Blue Origin Manufacturing, LLC has secured a major milestone in manufacturing with a newly patented method for structural assembly.
This innovation focuses on the patent titled ‘Friction stir additive manufacturing devices and methods for forming in-situ rivets’.
The patent describes a breakthrough in joining workpieces by utilizing a friction stir additive tool to deposit filler material into strategic through holes.

Revolutionizing Structural Joining

Abstract: A method of joining a first work-piece to a second work-piece is provided.
Each of the first work-piece and the second work-piece include a top surface, an opposed bottom surface, and a side surface connecting the top surface and the opposed bottom surface.
In one aspect, the method includes positioning the side surface of the first work-piece adjacent to the side surface of the second work-piece,
and advancing a friction stir additive manufacturing tool over the top surface of the first work-piece and the top surface of the second work-piece along a weld line between the first work-piece and the second work-piece.
As the friction stir additive manufacturing tool advances along the weld line, a filler material is deposited along the weld line and into a plurality of through holes formed in either or both of the first work-piece and the second work-piece.
Each of the plurality of through holes includes a first opening on the top surface, a second opening on the opposed bottom surface, and a pathway through the work-piece between the first opening and the second opening.
The method further includes joining the first work-piece and the second work-piece together.

Blue Origin’s advancement in friction stir additive manufacturing (FSAM) represents a major shift in how we approach the construction of large metallic structures. By integrating in-situ rivets directly into the welding method, this invention solves the historic challenge of joint deficiency in traditional butt welds. The ability to mechanically interlock components while simultaneously welding them provides a level of structural reliability that is critical for high tension environments like aerospace and heavy industry.

The genius of this patent lies in its dual-action capability. Traditional friction stir welding is already superior to fusion welding because it avoids melting the metal, thereby preserving the material properties of the alloy. However, by adding an additive component that fills pre-drilled holes, Blue Origin has created a hybrid joint that combines the molecular bonding of a weld with the mechanical strength of a rivet. This eliminates the need for secondary fasteners, reducing both weight and production time.

Swanson Reed has recognized this as the patent of the month because it targets a fundamental bottleneck in the creation of spaceflight hardware. In an industry where every gram of weight and every minute of production counts, a method that simplifies the bill of materials while increasing safety is a clear winner. This technology paves the way for more efficient construction of rockets and pressure tanks, setting a new benchmark for superb quality.

U.S. R&D Tax Credit Eligibility

This invention aligns with the U.S. R&D tax credit rules (Section 41) under the Four-Part Test:

• Permissible Purpose: The project aims to improve the durability and structural integrity of joined metallic components.
• Elimination of Uncertainty: The development requires overcoming technical uncertainty regarding the flow of filler material and the thermal impact on the rivet formation.
• Method of Experimentation: The team must perform iterative trials to evaluate different tool speeds and through-hole geometries to achieve a defect-free bond.
• Technological in Nature: The research relies on principles of metallurgy, mechanical engineering, and physics.

Practical Applications for R&D Tax Credits

1. Tool Geometry Research: Engineering unique tool shapes to ensure that the deposited filler material fully penetrates the through holes without creating voids or internal defects.
2. Material Compatibility Testing: Experimenting with various filler alloys to determine which metal combinations yield the highest tensile strength when paired with specific base metals like titanium or aluminum.
3. Thermal Control Optimization: Developing a cooling method to manage the heat generated during the friction stir method, preventing thermal deformation of the workpieces during the rivet deposition.