阅读说明：本技术 用于构造飞艇的方法和设备 (Method and apparatus for constructing an airship ) 是由 谢尔盖·布林 阿兰·韦斯顿 范阳阳 凯勒·凯普莱 里卡多·阿梅斯基塔 祖·汉 约翰·莫尔 于 2018-10-11 设计创作，主要内容包括：描述了用于快速且成本有效地构造飞艇的系统、设备和方法。在一个实施例中,飞艇结构可具有多个主框架,每个主框架包括互连的角锥体结构。角锥体结构中的一个可包括顶点接头、四个基部接头、第一连接器和第二连接器。顶点接头和基部接头均可具有构造成用于接收连接器的槽。顶点接头可具有四个顶点到基部的槽,并且每个基部接头可具有基部到顶点的槽和两个基部到基部的槽。第一连接器中的每个可使用顶点接头的顶点到基部的槽和基部接头的基部到顶点的槽中的一个将顶点接头连接到四个基部接头中的一个。第二连接器中的每个可使用由第二连接器连接的两个基部接头中的每个的基部到基部的槽中的一个连接四个基部接头中的两个。(Systems, devices, and methods for quickly and cost-effectively constructing an airship are described. In one embodiment, the airship structure may have a plurality of main frames, each main frame comprising an interconnected pyramid structure. One of the pyramid structures may include a vertex joint, four base joints, a first connector, and a second connector. The apex joint and the base joint may each have a slot configured to receive a connector. The apex joints may have four apex-to-base slots, and each base joint may have a base-to-apex slot and two base-to-base slots. Each of the first connectors may connect the vertex joint to one of the four base joints using one of the vertex-to-base slot of the vertex joint and the base-to-vertex slot of the base joint. Each of the second connectors may connect two of the four base subs using one of the base-to-base slots of each of the two base subs connected by the second connector.)

1. An airship structure, comprising:

a plurality of master frames, wherein each of the plurality of master frames comprises a plurality of interconnected pyramid structures, wherein a first pyramid structure of the plurality of interconnected pyramid structures comprises:

a vertex joint having a slot configured to receive a connector, wherein the slot of the vertex joint comprises four vertex-to-base slots;

four base tabs each having a slot configured for receiving a connector, wherein the slot of each of the base tabs comprises a base-to-apex slot and two base-to-base slots;

a plurality of first connectors, wherein each of the first connectors connects the vertex joint to one of the four base joints using one of the vertex-to-base slot of the vertex joint and the base-to-vertex slot of the base joint; and

a plurality of second connectors, wherein each of the second connectors connects two of the four base subs using one of the base-to-base slots of each of the two base subs connected by the second connector.

2. The airship structure of claim 1, wherein the first corner cone structure is adjacent to a second corner cone structure, wherein a first base joint and a second base joint of the four base joints of the first corner cone structure are base joints of the adjacent second corner cone structure.

3. The airship structure of claim 2, wherein one of the plurality of second connectors connecting the first base joint and the second base joint forms a side common to a first base of the first pyramid structure and a second base of the second pyramid structure.

4. The airship structure of claim 2, wherein the slot of the first base joint further comprises:

a second base-to-apex trough configured to connect to the apex joint of the second pyramid structure; and

a third base-to-base trough configured to connect to a third base joint of the second pyramid structure.

5. The airship structure of claim 4, wherein the slot of the first base joint further comprises:

a fourth base-to-base slot configured to connect to a fourth base joint of the second pyramid structure by a diagonal connector.

6. The airship structure of claim 2, wherein the slot of the first base joint further comprises:

three additional slots configured to be connected to three geodetic terminals of the geodetic structure, respectively.

7. The airship structure of claim 6, wherein the three geodetic joints are 4-way geodetic joints.

8. The airship structure of claim 6, wherein the three geodetic joints are 6-way geodetic joints.

9. The airship structure of claim 8, wherein one of the three geodesic joints is to form a base of a third pyramid structure of a gangway.

10. The airship structure of claim 2, wherein the slot of the first base joint further comprises:

a single slot configured to connect to a single geodesic connector.

11. The airship structure of claim 1, wherein the slot of the apex joint further comprises:

a first vertex-to-vertex slot configured to connect to a vertex joint of an adjacent second pyramid structure; and

a second vertex-to-vertex slot configured to connect to a vertex joint of an adjacent third pyramid structure, wherein the second pyramid structure and the third pyramid structure are located on opposite sides of the first pyramid structure.

12. The airship structure of claim 11, wherein the slot of the apex joint further comprises:

a third vertex-to-vertex slot configured to connect to a vertex junction of an adjacent fourth pyramid structure.

13. The airship structure of claim 12, wherein the fourth pyramid structure is part of a gangway.

14. The airship structure of claim 1, further comprising:

at least one gangway piece connecting a first main frame and a second main frame of the plurality of main frames, wherein the gangway piece comprises a plurality of interconnected second pyramid structures, wherein one of the second pyramid structures is adjacent to the first pyramid structure, wherein the first pyramid structure is one of the plurality of interconnected pyramid structures of the first main frame.

15. The airship structure of claim 14, wherein a common base joint is used to form a corner of the first pyramid structure and a corner of the second pyramid structure, wherein the common base joint is one of the four base joints of the first pyramid structure.

16. The airship structure of claim 15, wherein the common base joint is to form a corner of a third pyramid structure, wherein the third pyramid structure and the first pyramid structure are adjacent pyramid structures of the first main frame.

17. The airship structure of claim 16, wherein the common base joint comprises:

a second base-to-apex trough configured to connect to the apex joint of the second pyramid structure;

a third base-to-apex trough configured to connect to an apex junction of the third pyramidal structure;

a third base-to-base trough configured to connect to a first additional base joint of the second pyramid structure; and

a fourth base-to-base trough configured to connect to a first additional base joint of the third pyramid structure.

18. The airship structure of claim 17, wherein the common base joint comprises:

a fifth base-to-base slot configured to connect to one of the four base joints of the first pyramid structure other than the common base joint by a diagonal connector.

19. The airship structure of claim 18, wherein the common base joint comprises:

a sixth base-to-base slot configured to connect to a second additional base joint of the third pyramid structure by a diagonal connector.

20. The airship structure of claim 17, wherein the common base joint comprises:

an additional slot configured to connect to a geodetic connector of the geodetic structure.

21. The airship structure of claim 17, wherein the common base joint comprises:

an additional groove configured to connect to a geodesic connector for forming a base of the second pyramid structure.

22. The airship structure of claim 21, wherein the geodesic joint forms the base of the second pyramid structure by connecting to each of four base joints of the second pyramid structure, wherein the four base joints of the second pyramid structure comprise the common base joint and the first additional base joint of the second pyramid structure.

23. The airship structure of claim 1,

wherein the plurality of interconnected pyramid structures of each of the plurality of master frames are connected in a ring;

wherein the apex joints of the interconnected pyramid structures are interconnected by a plurality of third connectors; and is

Wherein the plurality of third connectors define a polygon.

24. The airship structure of claim 23,

wherein each of the vertex joints includes a pair of vertex-to-vertex slots configured for receiving two of the plurality of third connectors; and is

Wherein the pair of vertex-to-vertex slots of each of the vertex joints are angled relative to each other to form an inner vertex of the polygon defined by the plurality of third connectors.

25. The airship structure of claim 1, further comprising:

at least one gangway piece connecting a first main frame and a second main frame of the plurality of main frames, wherein the gangway piece comprises a plurality of interconnected second pyramid structures, wherein the bases of the second pyramid structures are located substantially in the same plane.

26. The airship structure of claim 1, wherein the apex joint and the four base joints are made of metal.

27. The airship structure of claim 1, wherein the apex joints and the four base joints are made of carbon fiber.

28. The airship structure of claim 27, wherein the apex joint comprises a male half and a female half, wherein the slot of the apex joint is formed by a profile of the male half and the female half.

29. The airship structure of claim 28, wherein each of the apex-to-base slots of the apex joint is formed by an internal concave surface of the male half and the female half.

30. The airship structure of claim 28, wherein the male half and the female half are each constructed by pressing carbon fiber twill between dies.

31. The airship structure of claim 30, wherein the mold is configured using 3D printing.

32. A jig for constructing a main frame of an airship structure, comprising:

a first rail and a second rail configured to be parallel to each other, the first rail and the second rail each forming an arc;

a plurality of first support structures coupled to the first rail, wherein the plurality of first support structures have a non-uniform height to support a curvature of the arc of the first rail; and

a plurality of second support structures coupled to the second rail, wherein the plurality of second support structures have a non-uniform height to support a curvature of the arc of the second rail;

wherein the first and second tracks are configured to interface with a detachable wheel coupled to an outer surface of the main frame and enable the main frame to rotate on the jig along an axis of the main frame.

33. The clamp of claim 32, wherein the arc formed by each of the tracks has a curvature that substantially matches a curvature of an outer portion of the main frame.

34. The clamp of claim 32, wherein the first and second support structures have a fixed height.

35. A clamp according to claim 32 wherein the first and second support structures are individually adjustable with respect to their height.

36. The clamp of claim 35, wherein each of the first support structures comprises:

an attachment portion coupled to a portion of the first rail; and

an adjustment platform coupled to a body of the clamp.

37. The jig of claim 32, wherein the mainframe comprises a plurality of interconnected pyramid structures, wherein the outer surface of the mainframe is formed by bases of the plurality of interconnected pyramid structures, wherein the detachable wheels are coupled to the bases.

38. The clamp of claim 32, further comprising:

a driving unit configured to rotate the main frame placed on the jig;

wherein the drive unit is controlled by a computer.

39. The clamp of claim 32, wherein the computer is configured to synchronously control one or more additional drive units of one or more additional clamps, respectively.

Technical Field

The present disclosure relates generally to airships or lighter-than-air aircraft, and more particularly to apparatus, methods and systems for constructing the airships or aircraft.

Background

An airship is a lighter-than-air aircraft that obtains the lift required for flight based on buoyancy generated by a gas having a density less than the surrounding air. Typically, airships include a structure attached to a skin that holds a lifting gas (such as helium or hydrogen). Some airships (such as rigid or semi-rigid airships) may have a structural frame to help maintain the shape of the skin.

Disclosure of Invention

Embodiments disclosed herein relate to systems, devices, and methods for providing a fast and cost-effective way to construct an airship. In particular embodiments, the frame structure of the airship may be constructed using pre-constructed joints designed to facilitate and simplify construction. In certain embodiments, the joint may be manufactured using 3D printing or other additive manufacturing processes. For example, 3D printing may be used to create a mold for the joint. The mold may then be pressed against a sheet of carbon fiber twill, which once hardened, may be used to create a joint for an airship structure.

Further embodiments described herein enable the airship to be built on the ground, thereby enhancing construction safety, speed, and cost. In a particular embodiment, the detachable wheels may be attached to the outer surface of a main frame, which may be circular in shape when constructed. The partially assembled main frame may then be placed on a semi-circular jig with the attached wheels abutting the jig. Thus, this configuration allows the main frame to rotate when assembled on the ground by a worker without exposing the worker to unnecessary risks.

The embodiments disclosed herein are merely examples, and the scope of the present disclosure is not limited thereto. Particular embodiments may include all, some, or none of the components, elements, features, functions, operations, or steps of the above-disclosed embodiments. The dependencies or references in the appended claims are chosen for formal reasons only. However, any subject matter resulting from an intentional reference to any preceding claim (in particular a plurality of dependent claims) may also be claimed such that any combination of a claim and its features is disclosed and may be claimed irrespective of the dependent claims selected in the appended claims. The claimable subject matter comprises not only the combination of features as set forth in the appended claims, but also any other combination of features in the claims, wherein each feature mentioned in the claims may be combined with any other feature or combination of features in the claims. Furthermore, any embodiments and features described or depicted herein may be claimed in a separate claim and/or in any combination with any embodiment or feature described or depicted herein or with any feature of the appended claims.

Drawings

Fig. 1 shows an example of the structure of a rigid airship.

Fig. 2A shows an example of a main frame of a rigid airship.

Fig. 2B shows an example of a boat body segment of a rigid airship.

Fig. 3A shows an example of a portion of a main frame of a rigid airship.

Figure 3B shows an example of a portion of a gangway element of a rigid airship.

Fig. 3C shows an example of a portion of a geodesic structure of a rigid airship.

Fig. 3D shows an example of a portion of the hull section where the main frame intersects the ramp.

Fig. 4A to 4C show an example of a pyramid structure of the main frame.

Fig. 5A to 5B show examples of apex joints of pyramid structures used to construct the main frame.

Fig. 6A to 6C show examples of equidistant configurations of a mold and components of the apex joint of the main frame manufactured using the mold.

Fig. 7A to 7F show examples of a mold for manufacturing the apex joint of the main frame.

Fig. 8A to 8C show examples of equidistant configurations of the molds for manufacturing the apex joint of the main frame.

Fig. 9A to 9E show examples of base joints of pyramid structures for constructing a main frame.

Fig. 10A to 10D show examples of equidistant configurations of a mold and a component of a base joint of a main frame manufactured using the mold.

Fig. 11A to 11F show an example of a mold for manufacturing the base joint of the main frame.

Fig. 12A to 12D show examples of equidistant configurations of the dies for manufacturing the base joint of the main frame.

Fig. 13A-13B illustrate examples of apex joints for pyramid structures used to construct gangway pieces.

Fig. 14A to 14F show examples of molds for manufacturing apex joints of gangways.

Fig. 15A to 15G show examples of base joints of the pyramid structure of the gangway.

Fig. 16A to 16B show an example of a mold for manufacturing a base-geodesic piece of a base joint of a pyramid structure of a gangway piece.

Fig. 17A to 17B show an example of a mold for manufacturing apex-geodesic pieces of base joints of pyramid structures of gangway pieces.

Fig. 18A to 18B show examples of 4-way geodesic connectors.

Fig. 19A to 19B show an example of a 6-way geodesic connector.

Fig. 20A to 20B show an example of an extension joint for the apex joint of the pyramid structure of the main frame.

Fig. 21 shows an exploded view of an example of an extension joint for the apex joint of the pyramid structure of the main frame.

Fig. 22A to 22B show an example of a mold for manufacturing a top part of an extension joint for an apex joint of a pyramid structure of a main frame.

Fig. 23 shows an example of a male mould for manufacturing the top part of the extension joint for the apex joint of the pyramid structure of the main frame.

Fig. 24A-24C show examples of main frame to ramp and geodesic extension joints attached to the base joint of the main frame.

Figure 25 shows an exploded view of an example of a main frame to gangway and geodesic extension joint.

Fig. 26A-26B show examples of apex components of the main frame to the gangway and geodesic extension joints.

Fig. 27A to 27B show an example of a mould for making the apex part of the main frame to the extension joint of the gangway and geodesic.

Fig. 28A to 28B show examples of central parts of the main frame to ramp and geodesic extension joints.

Fig. 29A to 29B show an example of a mold for manufacturing a center part of the extension joint of the main frame to the gangway piece and the geodesic line.

Fig. 30A to 30B show examples of base parts of the main frame to the extension joints of the gangway and geodesic.

Fig. 31A to 31B show an example of a mold for manufacturing a base part of a main frame to extension joint of a gangway piece and geodesic.

Fig. 32 shows an exploded view of an example of a main frame to geodesic extension joint.

Fig. 33A to 33B show an example of a top part of the extension joint of the main frame to the geodetic line.

Fig. 34A to 34B show an example of a mold for manufacturing a top part of a main frame to geodesic extension joint.

Fig. 35A to 35B show an example of a bottom part of the extension joint of the main frame to the geodesic line.

Fig. 36A to 36B show an example of a mold for manufacturing a bottom part of a main frame to geodesic extension joint.

Fig. 37A shows an example structure of a rigid airship.

Fig. 37B shows an embodiment of the main frame.

Fig. 38 shows an example perspective view of a portion of a main frame.

FIG. 39A shows an example top view of a portion of an alternative geodesic structure.

Fig. 39B illustrates an alternative embodiment of a portion of the hull structure with the main frame intersecting the ramp.

Fig. 40A-40B show different perspective views of alternative embodiments of apex joints for use in constructing the pyramid structures of the main frame.

Fig. 41A-41B show different perspective views of alternative embodiments of the main frame to geodesic base joint for constructing the pyramid structure of the main frame.

Fig. 42 shows an alternative embodiment of the apex joint for constructing the pyramid structure of the gangway piece.

Fig. 43A-43B show different perspective views of embodiments of the gangway to geodesic base joint of the pyramid structure of the gangway.

Fig. 44 shows an alternative embodiment of a 6-way geodesic connector.

Fig. 45A-45B show different perspective views of embodiments of the gangway to main frame base joint.

Fig. 46A-46B show different perspective views of an embodiment of the main frame-ramp-base-geodesic joint.

Fig. 47A-47B show different perspective views of embodiments of the base joint of the pyramid structure of the gangway.

Fig. 48A-48B show different perspective views of an embodiment of a main frame to geodesic base joint.

Figures 49A-49B show different perspective views of embodiments of the apex joint of the gangway to the main frame.

FIG. 50 illustrates an embodiment of a main frame to geodesic joint.

Fig. 51A-51B show different perspective views of an embodiment of a main frame base joint having nine connector slots.

Fig. 52A-52B show different perspective views of an embodiment of a main frame to geodesic base joint.

Fig. 53A-53B show different perspective views of an embodiment of a main frame to geodesic base joint having eight connector slots.

Fig. 54 shows an embodiment of the main frame assembled on the roller coaster jig.

Fig. 55A to 55B show an embodiment of a roller coaster clamp.

FIG. 56 illustrates an embodiment of an adjustable support structure for a roller coaster clamp.

Fig. 57A-57B illustrate an embodiment of a detachable wheel for connecting the main frame with the roller coaster clamp.

Detailed Description

Certain embodiments described herein relate generally to the construction and design of components for constructing rigid or semi-rigid airships. Fig. 1 shows an example structure 100 of a rigid airship. The structure 100 may include a boat section 110, a bow section 120, and a stern section 130 to which the rudder of an airship may be attached. The structure 100 may include a plurality of primary transverse frames or main frames 140. In a particular embodiment, each mainframe 140 is circular. In a particular embodiment, the main frames 140 may be interconnected using longitudinal gangway pieces 150. In particular embodiments, wires connecting points on the inner perimeter of each main frame 140 (e.g., which may be constructed using Vectran fibers or any other suitable material having suitable strength and flexibility characteristics) may physically divide hull 110 into multiple segments. These segments can be used to hold separate bladders containing a lift gas (e.g., helium).

FIG. 2A illustrates an example mainframe 140. The mainframe 140 may include an outer portion 210 and an inner portion 220. In a particular embodiment, the mainframe 140 may be constructed using a pyramid structure 250. Each pyramid structure 250 may have a base and an apex. In particular embodiments, the pyramid structure 250 may be configured such that its apex points toward the center of the mainframe 140 and its base faces outward. In this configuration, the outer portion 210 of the mainframe 140 is formed by connectors that form the bases of the pyramid structures 250, and the inner portion 220 of the mainframe 140 is formed by connectors that connect the vertices 270 of those pyramid structures 250.

Fig. 2B shows an example boat body section 280. In particular embodiments, hull section 280 may be substantially cylindrical. Each opening of the cylindrical boat section 280 can be constructed using the mainframe 140. In a particular embodiment, the gangway pieces 285 may connect the main frame 140. Any number of ramp pieces 285 may be used (e.g., one, two, four, five, eight, etc.). For example, if four ramp pieces 285 are used, they may be evenly spaced along the circumference of the main frame 140. In particular embodiments, each channel may be constructed using a pyramid structure. The pyramid structures of the gangway pieces 285 may be similar to those used to construct the main frame 140, but differ in that the pyramid structures of the gangway pieces 285 may form substantially straight structures (e.g., the bases of the pyramid structures of the gangway pieces 285 are in the same plane), while the pyramid structures of the main frame 140 may form rounded structures. In a particular embodiment, the two mainframes 140 of the submarine segment 280 may be positioned and aligned in parallel according to their respective pyramid structures. In this arrangement, each pair of corresponding pyramid structures in the two mainframes 140 may be connected. In the example shown in fig. 2B, a series of longitudinal connectors 290 may connect the inner base joint of each pyramid structure in one mainframe to a corresponding inner base joint in another mainframe. In particular embodiments, longitudinal connectors 290 and X-pattern structures 295 may form a geodesic structure to create a wall for hull 280.

Fig. 3A shows an example perspective view of a portion of the mainframe 140. In a particular embodiment, each pyramid structure 250 used to build the mainframe 140 may have four base joints (e.g., 301, 302, 303, and 304) that form the base of the pyramid (e.g., 250a) and a vertex joint (e.g., 305) that forms the vertex of the pyramid. In a particular embodiment, a connector or rod may connect the joints to form the pyramid structure 250. For example, the base of the pyramid 250a may be formed by a connector 311 connecting the base joints 301 and 302, a connector 312 connecting the base joints 302 and 303, a connector 313 connecting the base joints 303 and 304, and a connector 314 connecting the base joints 304 and 301. The sides of the pyramid 250a may be formed by connectors 315, 316, 317, and 318, which connect the apex joint 305 to the base joints 301, 302, 303, and 304, respectively. In certain embodiments, the mainframe 140 may be constructed using adjacent pyramid structures 250. For example, between two adjacent pyramids 250, one connector (e.g., 314) may be shared between the bases of two pyramids 250a and 250 b. In such a configuration, two adjacent pyramids may share one base connector and two corresponding base joints. For example, fig. 3A shows the base fittings 301 and 304 and their connectors 314 shared by two marked pyramids 250a and 250 b. In a particular embodiment, the vertex junctions (e.g., 305 and 355) of adjacent pyramids (e.g., 250a and 250b, respectively) may be connected by a vertex connector 320. In a particular embodiment, the structural pattern of the interconnected pyramid structures 250 described above is repeated throughout the master frame 140. In particular embodiments, the joints may be configured to create a circular mainframe 140. For example, the vertex joint 305 may be configured such that its slots for receiving the vertex-to- vertex connectors 320 and 321 may be angled relative to each other to form corners of a polygon that approximates the interior of the circular main frame 140. Similarly, each base fitting (e.g., 301-304) may be configured such that its two slots for receiving base connectors forming respective sides of adjacent pyramids may be angled with respect to each other to form a polygonal corner approximating the exterior of the circular mainframe 140. For example, the base fitting 301 may be configured such that the connectors 311 and 361 form the corners of a 36-sided polygon. Further details of the construction of the joint are provided below.

In certain embodiments, the connectors (e.g., 311-318, 320, and 321) may be constructed using a composite of carbon fiber layers sandwiched by another core, such as honeycomb

Or any other suitable material having a high strength to weight ratio. For example, the connector may be cylindrical with a hollow cylindrical center (in other words, it may be a tube). The outer and inner surfaces of the hollow cylindrical connector may be made of carbon fiber layers, which may be used, for example, in the form of honeycomb

The sandwich core material of (1). In particular embodiments, the carbon fiber layers may be pre-impregnated carbon fiber layers, approximately 0.5 mm to 0.75 mm thick, and the diameter of the composite carbon fiber connector may be approximately 30 mm to 400 mm. In particular embodiments, the composite connector may be manufactured by infusing carbon fiber layers with epoxy and sandwiching the layers in a honeycomb form

And manufacturing the periphery. The sandwich material may then be wrapped around the cylindrical mold until the material hardens to form the connector. The resulting connector has several desirable characteristics for airship construction, including, for example, strength, stiffness, and extremely light weight.

Fig. 3B shows an example perspective view of a portion of the ramp member 285 assembly. Similar to the main frame 140, in certain embodiments, the gangway pieces 285 may be constructed using an interconnected pyramid structure. One of the pyramid structures 398 shown has a vertex joint 375 and a base with base joints 371, 372, 373, and 374. The apex joint 375 may be connected to the apex joints of two adjacent pyramid structures via connectors 380 and 381, respectively. The four base connectors 371 and 374 may be interconnected via connectors 391 and 394, as shown. The apex joint 375 and the base joint 371 and 374 may be configured to form a substantially straight ramp structure 285. For example, apex joint 375 may be configured such that the slots thereof for receiving apex-to-apex connectors 380 and 381 may align to form a straight line. Similarly, each of the base joints 371 and 374 may be configured such that its two slots for receiving base connectors forming corresponding sides of adjacent pyramids align to form a straight line (e.g., base joint 372 may be configured such that connectors 391 and 395 form a straight line).

Figure 3C illustrates an example top view of a portion of geodesic structure 399. As described above, the mainframe 140 may be connected by the longitudinal connectors 290. In a particular embodiment, the two base joints of the mainframe 140 may be connected by a single longitudinal connector 290 that extends through a series of geodesic joints (e.g., the 6-way geodesic joint 330). Alternatively, the two base joints may be connected by a series of longitudinal connectors which are connected by joints to form a substantially straight line. In a particular embodiment, the 6-way geodesic connector 330 may have six connector slots. Two slots on opposite sides of the fitting 330 may form a channel through which the longitudinal connector 290 may pass. The other four connector slots of the 6-way geodesic connector 330 may be configured to connect to four 4-way geodesic connectors 335, respectively, to form a geodesic structure. In a particular embodiment, each 4-way geodesic connector 335 may be used as an intersection of four connectors to form an "X" pattern, which in turn may be configured to connect two adjacent longitudinal connectors 290. In a particular embodiment, an end of the geodesic structure 399 may be connected to a connection tab 339. In certain embodiments, the connection fitting 339 may be configured with three connector slots, as shown in fig. 3C. In a particular embodiment, the connection joint 339 may include a mainframe to geodesic extension (e.g., fig. 32) having an interface surface configured to surround an outer surface of a base joint (e.g., 301) of the mainframe 140. In certain embodiments, an adhesive or other attachment means (e.g., screws) may be used to secure the extension of the mainframe to the geodesic wire to the base joint 301 of the mainframe 140.

Fig. 3D illustrates an example of a portion of the hull structure shown in fig. 2B, where the main frame 140 (formed in part by pyramid structures 341, 340, and 342) intersects with the gangway 285 (formed in part by pyramid structure 343). Referring back to fig. 2B, two main frames 140 may be connected by one or more gangway pieces 285. In a particular embodiment, both the main frame 140 and the gangway 285 may be constructed using a pyramid structure. Thus, at the intersection point between the main frame 140 and the gangway 285, the pyramid structure of the main frame 140 (hereinafter referred to as "intersecting main frame pyramid structure") may require additional slots to connect to or support the pyramid structure of the gangway 285 (hereinafter referred to as "intersecting gangway pyramid structure"). For example, fig. 3D illustrates that the intersecting main frame pyramid structure 340 may be adjacent to three pyramid structures: two main frame pyramid structures 341 and 342 and one intersecting gangway pyramid structure 343. In a particular embodiment, the apex 349 of the intersecting main frame pyramid structure 340 may have additional connector slots for connecting to the apex of the intersecting ramp pyramid structure 343. In a particular embodiment, the apex 349 of the intersecting mainframe pyramid structure 340 may include an extended groove for the apex joint of the mainframe pyramid structure, such as the pyramid structures shown in fig. 20A-20B. Furthermore, the internal base joint 359 of the intersecting main frame pyramid structure 340 may have additional connector slots to connect to (1) the apex of the intersecting gangway pyramid structure 343, (2) the base joint of the intersecting gangway pyramid structure 343, and (3) the 4-way geodesic joint 335 of the geodesic structure. In a particular embodiment, the internal base joint 359 of the intersecting mainframe pyramid structure 340 may include a mainframe to ramp and geodesic extension (e.g., fig. 24A-24B) having an interface surface configured to surround the outer surface of the base joint (e.g., 301) of the mainframe 140. Fig. 3D also shows the base joint 1500 of the pyramid structure 343 of the gangway. The description of this base joint 1500 is further described below with reference to fig. 15A-15G.

Fig. 4A to 4C show an example of the pyramid structure 250 of the mainframe 140. Fig. 4A shows a perspective view, fig. 4B shows a top view, and fig. 4C shows a side view. In particular embodiments, apex joints 305 may be configured to connect to six connectors, four connectors (e.g., 315, 316, 317, and 318) for connecting with base joints (e.g., 301, 302, 303, and 304), respectively, and two connectors (e.g., 320 and 321) for connecting with apex joints of adjoining pyramid, respectively. In a particular embodiment, a base fitting (e.g., 301, 302, 303, or 304) may be shared by two pyramids and configured to connect to five connectors. One of the five connectors (e.g., 314) may be shared by the bases of two adjacent pyramids; two of the remaining connectors (e.g., 311 and 319) may respectively form sides of two adjacent bases that are perpendicular to the common connector 314; and the remaining two connectors (e.g., 315 and 329) may be connected to the vertices of two adjacent pyramids, respectively.

Fig. 5A and 5B show perspective views of examples of apex joints 305 of the pyramid structures used to construct the main frame. Fig. 5A is an assembled view of the joint 305, and fig. 5B is an exploded view of the joint. In particular embodiments, the apex joint 305 and the base joint (301-304) may be made of carbon fiber material and are structural units used to construct the airship. In a particular embodiment, the apex joint 305 may include a female half 501 and a male half 502. The female half 501 and the male half 502 of the apex joint 305 are configured to fit together, wherein the female half 501 substantially surrounds the male half 502 when the two halves are assembled, as shown in fig. 5A.

In particular embodiments, the assembled apex joint 305 may be configured with a slot for receiving a connector/rod. From the perspective shown in FIG. 5A, a slot 511 for receiving a vertex connector (e.g., connector 320 or 321 shown in FIG. 3A) is shown. The slot 511 may be formed by the separation between the female half 501 and the male half 502 when they are mated together. In particular embodiments, the slot 511 may be configured to receive and substantially surround a tubular object. In a particular embodiment, a similar slot 512 for receiving another vertex connector may be formed on the opposite end of the vertex joint 305. The opening or end of the slot (which is not visible from the perspective shown in fig. 5A) will be at 512. In a particular embodiment, slots 511 and 512 may be symmetric about an imaginary vertical plane that bisects apex joint 305 through the center between slot 511 and slot 512. In particular embodiments, each of the slots 511 and 512 may be substantially cylindrical. In certain embodiments that use pyramid structures to construct straight structures (such as the gangway pieces described below), the cylindrical slots for receiving the apex joints of the apex connectors may be aligned with one another to form straight lines (in other words, the axes of the cylindrical slots may coincide). On the other hand, in embodiments that use a pyramid structure to construct a circular main frame, such as the embodiment shown in FIG. 2, the outer angle (i.e., the angle measured from outside the fitting body, rather than through the body) between the two cylindrical grooves 511 and 512 (or their respective axes) may be less than 180 degrees. The particular angle depends on the geometry of the main frame. In a particular embodiment, the circular main frame may approximate a regular polygon (e.g., a 36-sided polygon). As such, the angle between the two connectors created by the vertex joint 305 may correspond to the vertex of a polygon or the interior angle of a corner. The angle may depend on the number of vertices/angles the polygon is designed to have. For example, the sum of the internal angles of the polygon may be determined based on the formula (n-2) × 180 degrees, where n is the number of vertices/angles of the polygon (the sum of the external angles of all vertices/angles of the polygon is 360 degrees). Thus, for example, each internal angle of a regular polygon may be determined based on the formula ((n-2) × 180)/n.

In particular embodiments, vertex sub 305 may also include a slot 513 for receiving a vertex-to-base connector (e.g., connector 315 shown in FIG. 3A). Similar to the apex connector slot 511, the apex-to-base slot 513 may be formed by the separation between the female half 501 and the male half 502 when they are mated together. In a particular embodiment, the apex joint 305 may have four such apex-to-base troughs to form a pyramid structure. Two paired apex-to- base slots 513 and 514 can be seen in fig. 5A. While the other two are hidden from view and are symmetrical to the slots 513 and 514. Since each side of the pyramid structure is triangular, the angle between each pair of vertices corresponding to the vertices of the triangular side to the base's trough depends on the desired geometric characteristics of the pyramid. For example, if the sides of the pyramid structure were identical equilateral triangles, the angle between each pair of vertices to the base's trough would be substantially 60 degrees.

In particular embodiments, the female half 501 and the male half 502 may be joined together using an adhesive or any other suitable adhesive. In certain embodiments, the two halves may be placed together and inserted with a connector/rod. In certain embodiments, a band or clamp may be used to apply an inward force such that the two halves are in close abutment with each other. In particular embodiments, each trough (e.g., 511, 513, etc.) may have one or more holes into which a liquid adhesive may be injected. For example, the slot 513 may have a hole in the female half 501 and another hole in the male half 502. When the two halves are placed together with the inserted rod/connector, liquid adhesive may be injected into one hole and air bubbles and/or excess adhesive may be allowed to escape from the other hole. This mechanism for joining the fitting and the parts of the connector may be applied to any of the fittings described herein.

Fig. 5B shows an exploded view of the apex joint 305, wherein the female half 501 is separated from the male half 502, along with a central plug 599 that may be placed in the interior cavity of the joint 305 to facilitate connector placement. In a particular embodiment, the female half 501 and the male half 502 are each symmetrical about a vertical plane passing through the axes of the slots 511 and 512. The two halves 501 and 502 may also be symmetrical about another vertical plane perpendicular to the above-mentioned vertical plane. Referring to the inner surfaces of the female half 501 and the male half 502 used to form the interior of the apex joint 305, in particular embodiments, the female half 501 may generally have a concave surface and the male half 502 may generally have a convex surface. In a particular embodiment, the inner surface of the apex joint 305 formed by the female half 501 and the male half 502 may have a placement guide (or plug) 599 that facilitates rod/connector placement.

In a particular embodiment, the top portions 551 of the slots 511 and 512 for the apex connectors may have semi-cylindrical interior concave surfaces (relative to the interior of the apex joint 305). The male half 502 may have a corresponding top portion 552 with an internal concave surface (opposite the interior of the apex joint 305). The inner concave surfaces of the top portions 551 and 552 of the female and male halves 501 and 501, respectively, form the inner surfaces of the grooves 511. In a particular embodiment, the female half 501 may have a flap portion 561 extending from a top portion 551. Similarly, the male half 502 may have a flap portion 562 extending from a top portion 552. When the two halves are placed together, the inner surfaces of the flap portions (relative to the interior of the apex joint 305) may abut one another, thereby creating sufficient surface area for bonding the two pieces together. In particular embodiments, the opposite ends of apex joint 305 may be symmetrically configured about the vertical plane described above.

For slots (e.g., 513 shown in fig. 5A) for a vertex-to-base connector, in a particular embodiment, the female half 502 may have a semi-cylindrical inner concave surface (e.g., 571) to form a top portion of each slot. Fig. 5B shows two concave surfaces 571 on one side of the female half 501, where the other two are hidden because they are on the other side of the fitting 305. The male half 502 may have a corresponding portion with an inner concave surface 572. The inner concave face 571 of the female half 501 and the inner concave face 572 of the male half 502 form the inner surfaces of the slots 513 and 514 for receiving the apex-to-base connector. In a particular embodiment, the female half 501 may have a portion 581 located between and extending from the female portions 571. Similarly, the male half 502 may have a portion 582 located between and extending from the recessed portion 572. When the two halves are placed together, the inner surfaces of these portions (581 and 582) may abut one another, thereby creating sufficient surface area for bonding the two parts together. In particular embodiments, opposite sides of the apex joint may be symmetrically configured about a plane orthogonal to the vertical plane described above.

Fig. 6A to 6C show examples of equidistant configurations of the female half 501 and the male half 502 of the apex joint 305 of the mold and the main frame. In particular embodiments, the mold itself may be manufactured using 3D printing, which provides a fast and cost-effective way of manufacturing. In particular embodiments, the mold may be configured such that both the female half 501 and the male half 502 may be manufactured simultaneously. In particular embodiments, a layer of carbon fiber twill or other suitable material may be placed between the molds to create the female half 501 and the male half 502 of the apex joint 305. For example, ten layers of carbon fiber material may be placed between outer female mold 601 and central mold 603, and another ten layers of carbon fiber material may be placed between central mold 603 and outer male mold 602. In particular embodiments, additional plastic sheets may be placed between the carbon fiber material and the mold to make it easier to remove the final product from the mold (e.g., in this case, the two halves of the apex joint). By pressing the sandwiched dies together and waiting for the pressed material to cure, the carbon fibre layer will conform to the contours defined by the dies and retain that shape. Thereafter, excess carbon fiber material may be trimmed.

Fig. 6A shows a side view of a mold and an embodiment of a female half 501 and a male half 502 produced by the mold. In a particular embodiment, the mold assembly may include an outer female mold 601, an outer male mold 602, and a center mold 603. The outer female mold 601 and the outer male mold 602 may form the outer surface of the apex joint 305 (or the outer surfaces of the female and male halves 501, 502 thereof) when placed together. Central mold 603 may define the interior profile of apex joint 305. In particular embodiments, central mold 603 may be configured to create placement guides on the inner surface of the apex joint to facilitate rod/connector placement. As shown in fig. 6A, portions of central mold 603 may define slots for receiving apex joints of rods/connectors. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, the center of the molds 601, 602, and 603 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or strengthen the structure of the mold. For example, cement may be poured into the hollow area in its tubular part 605 after the central mould 603 has been created. Fig. 6B shows a front view of the mold (601-. From this view, it can be seen that in certain embodiments, the tubular portion 610 of the central mold 603 corresponding to the slot for receiving the apex-to-apex connector can be made hollow along the longitudinal axis so that, for example, a steel rod can be inserted and used to provide press leverage. Fig. 6C shows a perspective view of the mold (601-. It should be understood from this view that the internal contours of the top portion 551 of the female half 501 and the top portion 552 of the male half 502 may be defined by the shape of the tubular portion 610 of the central mold 603. Similarly, the inner contours of the portions 571 and 572 of the female half 501 and the male half 502, respectively, may be defined by the shape of the tubular portion 605 of the central mold 603.

Fig. 7A to 7F show an example of a mold for manufacturing the apex joint 305 of the main frame. Fig. 7A shows a perspective view of the outer female mold 601. In particular embodiments, the outer female mold 601 may be hollow and may provide a cavity 719 into which cement or other filler material may be inserted. In a particular embodiment, a portion of the outer female mold 601 may have an inner concave surface 710 that defines an outer contour of the top portion 551 of the female half 501 of the apex joint 305. Fig. 7B shows a bottom view of the outer female mold 601. As can be seen from this view, in certain embodiments, the inner concave surface 710 defining the outer profile of the top portion 551 may be symmetrical about the vertical center plane described above. In particular embodiments, mold 601 may have an inner concave surface 721 that defines an outer profile of female half 501 corresponding to grooves 513 and 514. In particular embodiments, the mold 601 may have angled cuts 722 between the concave inner surfaces 721. This angled cut 722 may define the outer contour of the aforementioned portion 581 of the female half 501. The angled cutouts 722 also apply a force to corresponding angled cutouts of the male mold 602 when the molds are pressed together to help form the aforementioned portion 582 of the male half 502. In a particular embodiment, the concave inner surface 721 and the angled cut 722 may be symmetrically defined about a central vertical plane that is perpendicular to the vertical planes described above.

Fig. 7C shows a top perspective view of the outer male mold 602. In a particular embodiment, the mold 602 may have a front portion with an interior concave surface 730 (which is "interior" with respect to the interior space into which the carbon fiber material is pressed) that defines the exterior profile of the top portion 552 of the male half 502. In a particular embodiment, the mold 602 may have an interior concave surface 731 that defines an exterior profile of the male half 502 corresponding to the grooves 513 and 514. In a particular embodiment, the die 602 may have angled cuts 732 between the concave inner surfaces 731. This angled cut 732 may define the outer profile of the portion 582 of the male half 502. The angled cutouts 732 also exert a force on the corresponding angled cutouts 722 of the female mold 601 when the molds are pressed together to help form the aforementioned portions 581 of the female half 501. In a particular embodiment, the mold 602 may be symmetrical about a vertical central plane and about an orthogonal plane thereof. It should be understood that in the illustrated embodiment, the inner profile may be continuous. In particular embodiments, the interior corners and surface shapes of the mold may be designed to minimize negative draft, thereby allowing the pressed carbon fiber material to be more easily removed from the mold. In particular embodiments, the surface shape may also be configured to aid in achieving a uniform thickness of the pressed carbon fiber material. Fig. 7D shows a bottom perspective view of the outer male mold 602. In certain embodiments, the outer male mold 602 may be hollow and may provide a cavity 719 into which cement or other filler material may be placed.

Fig. 7E and 7F show perspective views of example components of central mold 603. In a particular embodiment, the central mold 603 may have two parts that may be separately manufactured (e.g., via 3D printing). Fig. 7E shows one of the two components, which will be referred to as left component 750, and fig. 7F shows the other component, which will be referred to as right component 760. In a particular embodiment, the left member 750 and the right member 760 may be assembled together to form the central mold 603. In a particular embodiment, left member 750 may have protruding pin 751 on a surface designed to interface with right member 760. To receive the protruding pin 751, the right member 760 may have a similarly shaped cavity 761 on its surface designed to interface with the left member 750. In certain embodiments, the protruding pins 751 and corresponding cavities 761 can be of an angled geometry, such as square (as shown), triangular, star-shaped, or any other shape to facilitate alignment. The left member 750 and the right member 760 may comprise the above-described tubular portion 610 of the central mold 603. As described above, in particular embodiments, the tubular portion 610 may have apertures (shown by openings at 752 and 762) extending along the length of the tubular portion 610 such that a rod may be inserted for leverage. In a particular embodiment, an aperture may extend through the pin 751 and its corresponding cavity 762.

As described above, the central mold 603 may have (1) a tubular portion 610 for forming a slot for receiving an apex connector and (2) a tubular portion 605 for forming a slot for receiving a top-to-base connector. In particular embodiments, the tubular portions (e.g., 610 and 605) may have "lips". For example, the tubular portion 610 may have downward lips 755 and 765 to bend the flaps 562 of the male half 502 downward (see, e.g., fig. 5B). As another example, tubular portion 605 may have lips 756 and 766 for guiding the carbon fiber material, e.g., for smooth transitions and/or improving manufacturing consistency. The lips guide portions of the carbon fiber material corresponding to the female half 501 and the male half 502 to abut against each other (e.g., 561 and 562; 581 and 582 in FIG. 5B). This creates an abutting surface area that can be used to bond the halves 501 and 502 together. The continuous profile of the female and male halves 501, 502 of the apex joint 305 created by the lip guidance can help reduce negative draft as it is removed from the mold.

Fig. 8A to 8C show examples of equidistant configurations of the molds for manufacturing the apex joint of the main frame. Fig. 8A shows an exploded view of the outer female mold 601, the central mold 603 and the outer male mold 602. Figure 8B shows a top perspective view of the assembled three molds 601 and 603. Figure 8C shows a bottom perspective view of the assembled three molds 601 and 603. As shown, due to the central mold 603, when the carbon fiber materials are pressed against each other, a slot for receiving the connector/rod is formed (as is apparent from the visible central mold 603 in the assembled view). As shown in fig. 8C, the lips (e.g., 755, 756, 766) direct the carbon fiber layers of the female half 501 and the male half 502 through a common continuous channel 801.

Fig. 9A to 9E show an example of a base joint 301 (which represents the base joints 302, 303, and 304 in fig. 3A) used to construct the pyramid structure of the main frame. Fig. 9A shows an assembled view, and fig. 9B to 9E show exploded views. In certain embodiments, the base fitting 301 may be made of carbon fiber or any other similar material. In a particular embodiment, the base fitting 301 can include a female half 901 and a male half 902. The female and male halves 901, 902 of the base fitting 301 are configured to fit together, wherein the female half 901 substantially surrounds the male half 902 when the two halves are assembled, as shown in fig. 9A. In certain embodiments, corresponding portions of the female half 901 and the male half 902 may be extended or bent in opposite directions to form the slots. For example, the base fitting 301 may have five slots 911, 912, 913, 914 (not fully visible in fig. 9A) and 915, which may be formed by the separation between the female and male halves 901, 902 when they are mated together. In certain embodiments, each of the slots 911, 912, 913, 914, and 915 may be configured to receive and substantially enclose a tubular object, such as a connector. In particular embodiments, each of slots 911, 912, 913, 914, and 915 may be substantially cylindrical.

In a particular embodiment, the base fitting 301 may have a total of five slots: a central slot 911 for receiving a connector (e.g., connector 314 shown in fig. 3A) that is common between the bases of two adjacent pyramids; a first side groove 912 and a first apex groove 913 for one pyramid; and a second side groove 914 (partially shown) and a second apex groove 915 for another pyramid. The side slots 912 may be configured to receive a connector (e.g., 311 in fig. 3A) that connects the base joint 301 of a first corner cone with an adjacent base joint (e.g., 302 in fig. 3A), and the apex slot 913 may be configured to receive a connector (e.g., 315 in fig. 3A) that connects the base joint 301 of the first corner cone with an apex joint (e.g., 305 in fig. 3A). Similarly, a side slot 914 (partially shown) may be configured to receive a connector (e.g., 361 in fig. 3A) that connects the base sub 301 of a second pyramid with an adjacent base sub (e.g., 352 in fig. 3A), and an apex slot 915 may be configured to receive a connector (e.g., 365 in fig. 3A) that connects the base sub 301 of that second pyramid with an apex sub (e.g., 355 in fig. 3A). In a particular embodiment, the base fitting 301 may be symmetric about an imaginary plane that bisects the base fitting 301 through the axis of the slot 911.

In certain embodiments that use pyramid structures to construct straight structures (such as the ramp pieces described below), the cylindrical side slots of the base joint (similar to slots 912 and 914) may be aligned with each other to form a straight line (in other words, the axes of the cylindrical slots may coincide). On the other hand, in embodiments where a pyramid structure is used to construct a circular master frame (e.g., an interconnected pyramid structure that forms a ring), such as the embodiment shown in fig. 2, the interior angle (i.e., the angle measured through the body of the joint) between two cylindrical side slots (or their corresponding axes) may be less than 180 degrees. In a particular embodiment, the circular main frame may approximate a regular polygon (e.g., a 36-sided polygon). In this way, the angle between the two connectors created by the base fitting 301 may correspond to the vertex of a polygon or the interior angle of a corner. The angle may depend on the number of vertices/angles the polygon is designed to have. For example, the sum of the internal angles of the polygon may be determined based on the formula (n-2) × 180 degrees, where n is the number of vertices/angles of the polygon (the sum of the external angles of all vertices/angles of the polygon is 360 degrees). Thus, for example, each internal angle of a regular polygon may be determined based on the formula ((n-2) × 180)/n.

As described above, the base fitting 301 may include a central slot 911 and two side slots 912 and 914. In a particular embodiment, the central slot 911 may be substantially perpendicular to each of the side slots 912 and 914. Also, as described above, the base joint 301 may form a corner joint of two adjacent pyramid structures, for example, as shown in fig. 3A. As such, the central slot 911, the side slots 912, and the apex slot 913 can define and support the corner structures of one pyramid, and the central slot 911, the side slots 914, and the apex slot 915 can define and support the corner structures of another pyramid. For each pyramid, such as the pyramid formed using the troughs 911, 912, and 913, the angle between the apex trough 913 and the center trough 911 and the angle between the apex trough 913 and the side troughs 912 depend on the desired geometric characteristics of the pyramid. For example, if each side of the pyramid structure is an equilateral triangle (the base of the pyramid is not referred to as a side), the angle between the apex groove 913 and the center groove 911 and the angle between the apex groove 913 and the side grooves 912 will both be substantially 60 degrees. In a particular embodiment, the corresponding structures for the other half of the base fitting 301 may have the same configuration.

In a particular embodiment, the female half 901 and the male half 902 may be joined together using an adhesive. In certain embodiments, the two halves may be placed together and inserted with a connector/rod. In certain embodiments, a band or clamp may be used to apply an inward force such that the two halves are in close abutment with each other. In certain embodiments, each slot (e.g., 911-. For example, the slot 913 may have a hole in the female half 901 and another hole in the male half 902. When the two halves are placed together with the inserted rod/connector, liquid adhesive may be injected into one hole and air bubbles and/or excess adhesive may be allowed to escape from the other hole.

Fig. 9B, 9C, 9D and 9E show exploded views of the base fitting 301, wherein the female half 901 is separated from the male half 902 from different angles. In a particular embodiment, the female half 901 and the male half 902 are each symmetric about a central plane extending from an axis of the slot 911, as discussed with reference to fig. 9A. With reference to the surfaces thereof used to form the interior of the base fitting 301, in a particular embodiment, the female half 901 may generally have a concave surface, while the male half 902 may generally have a convex surface. In certain embodiments, the inner surface of the base fitting 301 formed by the female half 901 and the male half 902 may have placement guides (or plugs) that facilitate rod/connector placement. In a particular embodiment, a plug.

In a particular embodiment, the top portion 951 of the female half 901 may have a concave inner face (relative to the interior of the base fitting 301) that is semi-cylindrical to form a top portion of each of the side grooves 912 and 914. The male half 902 may have a top portion 952 having an inner concave surface (relative to the interior of the base fitting 301). The inner concave surfaces of the top portions 951 and 952 of the female and male halves 901 and 902 form the inner surfaces of the grooves 912 and 914. In a particular embodiment, female half 901 can have a flap portion 961 extending from top portion 951. Similarly, the male half 902 may have a flap portion 962 extending from the top portion 952. When the two halves are placed together, the inner surfaces of the flap portions (relative to the interior of the base fitting 301) may abut each other, thereby creating sufficient surface area for bonding the two pieces together.

With respect to the base-to-apex channels (e.g., 913 and 915 in fig. 9A) of the base fitting 301, in particular embodiments, the female half 901 may have an inner concave surface 971 that is semi-cylindrical (relative to the interior of the base fitting 301) to form a top portion of each channel. The male half 902 may have a corresponding portion with an inner concave surface (relative to the interior of the base fitting 301) 972. The concave inner face 971 of the female half 901 and the concave inner face 972 of the male half 902 form the inner surfaces of the slots 913 and 915 for receiving connectors, respectively, that connect the apex joints 305 of adjacent pyramid structures. In particular embodiments, female half 901 may have a portion 981 located between and extending from female recesses 971. Similarly, the male half 902 may have a portion 982 located between and extending from the recessed portions 972. When the two halves are placed together, the inner surfaces of the portions (981 and 982) may abut each other, thereby creating sufficient surface area for bonding the two parts together.

Fig. 9D illustrates the back side of the base fitting 301 shown in fig. 9B, with the female half 901 separated from the male half 902. In a particular embodiment, the female half 901 and the male half 902 are each symmetric about a central plane extending from an axis of the slot 911 (see fig. 9A). With respect to the slot 911 of the base fitting 301, in a particular embodiment, the female half 902 may have a portion with a semi-cylindrical inner concave surface 991 (with respect to the interior of the base fitting 301) to form a top portion of the central slot 911. The male half 902 may have a corresponding portion with an inner concave surface 992 (relative to the interior of the base fitting 301). The inner concave surface 991 of the female half 901 and the inner concave surface 992 of the male half 902 form the inner surface of the central slot 911. In a particular embodiment, the female half 901 may have a flap portion 993 that extends from an inner concave surface 991 portion of the central slot 911. Similarly, the male half 902 may have a flap portion 994 extending from an inner concave surface 992 of the central slot 911. When the two halves are placed together, the inner surfaces of the flap portions (relative to the interior of the base fitting 301) may abut each other, thereby creating sufficient surface area for bonding the two pieces together.

Fig. 9E shows the underside of the base fitting 301, with the female half 901 separated from the male half 902. Additionally, fig. 9E shows a plug 999 that may be placed between the female half 901 and the male half 902. Once assembled, the plug 999 can be used to guide and maintain the placement of the connector.

Fig. 10A to 10D show examples of equidistant configurations of the female half 901 and the male half 902 of the base joint 301 of the mold and the main frame. In particular embodiments, the mold itself may be manufactured using 3D printing, which provides a fast and cost-effective way of manufacturing. In particular embodiments, the mold may be configured such that both the female half 901 and the male half 902 may be manufactured simultaneously. In particular embodiments, a layer of carbon fiber twill or other suitable material may be placed between the molds to create the female and male halves 901, 902 of the base joint 301. For example, ten layers (or any other suitable number of layers) of carbon fiber material may be placed between the outer female mold 1001 and the central mold 1003, and another ten layers of carbon fiber material may be placed between the central mold 1003 and the outer male mold 1002. In certain embodiments, an additional plastic sheet may be placed between the carbon fiber material and the mold to make it easier to remove the final product from the mold (e.g., in this case, the two halves of the base joint). By pressing the sandwiched dies together and waiting for the pressed material to cure, the carbon fibre layer will conform to the contours defined by the dies and retain that shape. Thereafter, excess carbon fiber material may be trimmed.

Fig. 10A and 10B show different side views of a mold and an embodiment of a female half 901 and a male half 902 produced by the mold. In a particular embodiment, the mold assembly may include an outer female mold 1001, an outer male mold 1002, and a central mold 1003. The female and male external molds 1001, 1002 may define the outer surfaces of the base joint 301 (or the outer surfaces of the female and male halves 901, 902 thereof) when placed together. The central mold 1003 may define the inner profile of the base sub 301. Similar to the central mold of the apex joint 305, the central mold 1003 occupies the interior area of the base joint 301 so that when the carbon fiber twill is pressed against each other by the female mold 1001 and the male mold 1002, the twill will not collapse onto each other. With the structural support of the central mold 1003, the carbon fiber twill will retain the desired shape defined by the mold until it hardens. In certain embodiments, the central mold 1003 may be configured to create placement guides on the inner surface of the base joint to facilitate rod/connector placement. As shown in fig. 10A, portions of the central mold 1003 may define slots for receiving rods/connectors. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, the center of the mold 1001, 1002, and 1003 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or strengthen the structure of the mold. For example, cement may be poured into the hollow area in its tubular portion 1005 after the central mould 1003 has been created. Fig. 10C shows a substantially frontal view of the mold (1001- > 1003) and the female and male halves 901, 902. From this view, it can be seen that in certain embodiments, the tubular portion 1010 of the central mold 1003 corresponding to the side slots for receiving the connectors may be made hollow along the longitudinal axis so that, for example, a steel rod may be inserted and used to provide press leverage. Fig. 10D shows a perspective view of the mold (1001 + 1003) and the male 902 and female 901 halves. It will be appreciated from this view that the internal contours of the top portion 951 of the female half 901 and the top portion 952 of the male half 902 may be defined by the shape of the tubular portion 1010 of the central mold 1003. Similarly, the internal contours of portions 971 and 972 of the female and male halves 901 and 902, respectively, may be defined by the shape of the tubular portion 1005. Likewise, the internal contours of portions 991 and 992 (shown more clearly in fig. 9E) of the female and male halves 901 and 902, respectively, may be defined by the shape of the tubular portion 1006.

Fig. 11A to 11F show an example of a mold for manufacturing the base joint 301 of the main frame. Fig. 11A shows a perspective view of the external female mold 1001. In certain embodiments, the external female mold 1001 may be hollow and may provide a cavity 1119 into which cement or other filler material may be placed. In a particular embodiment, a portion of the external female mold 1001 may have an internal concave face 1110 that defines an external contour of a top portion 951 of the female half 901 of the base fitting 301. Fig. 11B shows a bottom view of the outer female mold 1001. As can be seen from this view, in certain embodiments, the concave inner face 1110 defining the outer contour of the top portion 951 may be defined symmetrically about an imaginary vertical plane passing through the middle of the figure. In a particular embodiment, the mold 1001 may have an internal concave surface 1121 that defines an external profile of the female half 901 corresponding to the apex channels 913 and 915. The mold 1001 may also have an internal concave surface 1123 that defines an external profile of the female half 901 corresponding to the central slot 911. In a particular embodiment, the mold 1001 can have angled cuts 1122 between the inner concavities 1121. This angled cut 1122 may define the outer contour of the portion 981 of the female half 901.

Fig. 11C shows a top perspective view of the outer male mold 1002. In a particular embodiment, the mold 1002 may have a front portion with an inner concave surface 1130 (which is "interior" with respect to the interior space into which the carbon fiber material is pressed) that defines the outer profile of the top portion 952 of the male half 902. In particular embodiments, the mold 1002 may have an interior concave surface 1131 that defines an exterior contour of the male half 902 corresponding to the base-to-apex grooves 913 and 915 (see fig. 9A). In particular embodiments, the mold 1002 may have angled cuts 1132 between the inner concave surfaces 1131. This angled cut 1132 may define the outer contour of a portion 982 of the male half 902 (see fig. 9B). Figure 11D shows a bottom perspective view of the outer male mold 1102. In certain embodiments, the outer male mold 1002 may be hollow and may provide a cavity 1149 into which cement or other filler material may be placed. In a particular embodiment, the die 1002 may have inner concave surfaces 1141 on opposite sides of the angled cut portion 1132, as shown in fig. 11C. The inner recessed surface 1141 may define an outer profile of the male half 902 corresponding to the central slot 911 (see fig. 9A). In a particular embodiment, the mold 1002 may be symmetric about an imaginary central plane passing through the middle of the surface 1141 that divides the mold 1002 into symmetric halves. It should be understood that in the illustrated embodiment, the inner profile may be continuous. In particular embodiments, the interior corners and surface shapes of the mold may be designed to minimize negative draft, thereby allowing the pressed carbon fiber material to be more easily removed from the mold. In particular embodiments, the surface shape may also be configured to help the pressed carbon fiber material have a uniform thickness.

Fig. 11E and 11F show perspective views of example components of central mold 1003. In a particular embodiment, the central mold 1003 may have two parts that may be separately manufactured (e.g., via 3D printing). Fig. 11E shows one of the two components, which will be referred to as the left component 1150, and fig. 11F shows the other component, which will be referred to as the right component 1160. In a particular embodiment, the left component 1150 and the right component 1160 may be assembled together to form the central mold 1003. In a particular embodiment, left member 1150 may have a protruding pin 1151 on a surface designed to interface with right member 1160. To receive protruding pin 1151, right member 1160 may have a similarly shaped cavity 1161 on its surface designed to interface with left member 1150. In certain embodiments, the protruding pins 1151 and corresponding cavities 1161 may be of an angled geometry, such as square (as shown), triangular, star-shaped, or any other shape to facilitate alignment. In a particular embodiment, the left component 1150 and the right component 1160 of the central mold 1003 comprise the above-described tubular portion 1010 of the central mold 1003. As described above, in certain embodiments, the tubular portion 1010 may have an aperture (shown as openings 1152 and 1162) extending along the length of the tubular portion 1010 such that a rod may be inserted for leverage compression. In a particular embodiment, an aperture can extend through pin 1151 and its corresponding cavity 1162.

As described above, central mold 1003 may have (1) tubular portion 1010 for forming the side channels, (2) tubular portion 1005 for forming the apex channels, and (3) tubular portion 1006 for forming the central channel. In the embodiment shown in fig. 11E and 11F, the left and right members 1150 and 1160 each have one of (1) one of the tubular portions 1010a and 1010b, (2) one of the tubular portions 1005a and 1005b, and (3) one of the halves (denoted by 1006a and 1006b) of the tubular portion 1006. In a particular embodiment, the tubular portions (e.g., 1010a, 1010b, 1005a, 1005b, 1006a, and 1006b) can have a "lip". For example, each of the tubular portions 1010a and 1010b may have a downward lip 1155a and 1155b, respectively, to bend the flap 962 downward. As another example, tubular portions 1005a and 1005b may have lips 1166a and 1166b, respectively, for guiding the carbon fiber material, e.g., for smooth transitions and/or to improve manufacturing consistency. Similarly, the tubular portions 1006a and 1006b can have lips for similar functional purposes (e.g., portion 1006a can have lip 1156; the lip of portion 1006b can be hidden from view). The lips guide portions of the carbon fiber material corresponding to the female half 901 and the male half 902 to be placed against each other (e.g., 961 and 962 in fig. 9B; 981 and 982 in fig. 9B; 993 and 994 in fig. 9E). This creates an abutting surface area between the two halves. The continuous profile of the female 901 and male 902 halves of the base fitting 301 created by the lip guidance can help reduce negative draft when the halves are removed from their molds.

Fig. 12A-12D illustrate example isometric configurations of a mold for making a base joint of a main frame. Fig. 12A and 12B show exploded views of the outer female mold 1001, the central mold 1003 and the outer male mold 1002 from opposite sides. Fig. 12C and 12D show perspective views of the mold 1001 and 1003 once assembled together. Referring to fig. 12C, due to the central mold 1003, when the carbon fiber materials are pressed against each other, a slot for receiving a connector/rod may be formed (as indicated by the central mold 1003 visible in the assembled view). The lips (e.g., 1155a, 1155b, 1166a, 1166b, and 1156) direct the carbon fiber layers of the female half 901 and the male half 902 through a common continuous channel 1201.

Fig. 13A-13B illustrate an example of a vertex joint 375 for use in constructing a pyramid structure of a gangway (such as the structures shown in fig. 3B and 3D). The apex joint 375 of the pyramid structure of the gangway piece is similar to the apex joint 305 of the pyramid structure of the main frame. The apex joint 375 has a female half 1301 and a male half 1302. When assembled, female half 1301 and male half 1302 form six slots for connecting to other fittings. Four notches are apex-to-base slots (slots 1313 and 1314 are shown, while the other two notches are hidden from view, which is symmetrical to slots 1313 and 1314). The other two notches 1311 and 1312 are apex-to-apex slots. While these apex-to-apex slots are similar to those of the apex joint 305 of the main frame, they differ in that their axes are aligned to form a straight continuous opening through which a single connector (e.g., connector 290, as shown in fig. 2B) can pass. Figure 13B shows an exploded view of the apex joint 375. The features of the split halves 1301 and 1302 are similar to those of the apex joint 305 of the main frame and therefore will not be repeated for the sake of brevity.

Fig. 14A-14F illustrate an example of a mold for the apex joint 375 of a gangway. The features of the mold are similar to those of the mold for the apex joint 305 of the main frame (e.g., as shown in fig. 7A-7F). The main difference is that the mold for the apex joint 375 of the gangway piece is configured to create apex-to-apex slots that are straight relative to each other, as described above. For example, fig. 14A and 14B show perspective and bottom views, respectively, of an outer female mold 1401 for an apex joint 375 of a gangway piece. As shown in fig. 14B, an external female mold 1401 for an apex joint 375 of a gangway piece may have an internal concave surface 1410 that defines the external contour of the top portion of the female half 1301 of the apex joint 375. The concave inner face 1410 passes substantially straight through the die. In contrast, the concave inner face 710 (see FIG. 7B) of the outer female mold 601 for the apex joint 305 of the main frame has two separate segments that are slightly angled with respect to each other. As shown in fig. 14C (perspective view) and 14D (bottom view), the male outer mold 1402 for the apex joint 375 of the gangway piece may also be configured to produce aligned apex-to-apex slots. For example, both ends of the outer male mold 1402 may have concave inner surfaces 1430 ("inner" with respect to the interior space of the pressed carbon fiber material) that define the outer contour of the top of the male half 1302 of the apex joint. The concave inner surface 1430 at each end may be flush with the other end. Fig. 14E and 14F show that the central mold 1403 of the apex joint 375 of the gangway piece may have a left part 1450 and a right part 1460, respectively. The tubular portions 1410a and 1410b of the left and right members 1450 and 1460, respectively, may define straight tubular interiors for the apex-to-apex slots. The process of using these molds to create the apex joint 375 of the gangway piece is similar to the process of creating the apex joint 305 of the main frame. For example, similar to the configuration and process shown in fig. 6A-6C, carbon fiber material may be pressed therebetween using outer female mold 1401, central mold 1403, and outer male mold 1402 to form female half 1301 and male half 1302 of apex joint 375. Female half 1301 may be formed between outer female die 1401 and central die 1403, and male half 1302 may be formed between central die 1403 and outer male die 1402.

Fig. 15A-15G show an example of a base joint 1500 of a pyramid structure of a gangway (see, e.g., fig. 3D, reference numeral 343). The pyramid structure 343 of the gangway piece may be configured adjacent to the geodesic structure as shown in fig. 3D. Thus, in the embodiment of the base joint 1500 of a gangway, the base joint 1500 comprises seven slots to support two adjoining gangway pyramids and adjoining geodesic structures. The base-to- base slots 1501, 1502, and 1503 are configured to support connectors that form the bases of two adjoining ramp pyramid, which will be referred to as ramp pyramids a and B. In particular, the troughs 1502 are used to form the sides that are common between the bases of adjacent ramp pyramid a and B, and the troughs 1501 and 1503 are used to form the sides of two adjacent ramp pyramids on the same side of the ramp, respectively. The base-to- apex slots 1506 and 1507 are used to connect the base joint 1500 to the apexes of two adjoining ramp pyramid respectively. For example, the trough 1506 may be used to connect to the apex of pyramid a and the trough 1507 may be used to connect to the apex of pyramid B. The base sub 1500 may also have base-to- geodesic slots 1504 and 1505 for connecting the base sub 1500 to an adjoining geodesic structure. The geodesic structures may be configured to form multiple "X" patterns (see fig. 3C and 3D). The base-to- geodesic slots 1504 and 1505 may be configured to receive connectors from different "X" patterns. For example, slot 1504 may be used to connect to the bottom of the "\" portion of one "X" pattern, and slot 1505 may be used to connect to the bottom of the "/" portion of another "X" pattern. Grooves 1501-1505 are all substantially in the same plane. On the other hand, the base-to- apex troughs 1506 and 1507 used to form the sides of the pyramid are configured to form an angle with this plane.

In a particular embodiment, the base joint 1500 of the pyramid structure of the gangway piece can be constructed using three parts: base and geodesic features 1510, base and apex features 1520, and apex and geodesic features 1530. The base slots 1501 and 1503 may be formed using all three pieces. The base slots 1502 may be formed using base and geodesic features 1510 and base and apex features 1520. Base-to- apex slots 1506 and 1507 are formed using base and apex feature 1520 and apex and geodesic feature 1530. Base-to- geodesic slots 1504 and 1505 are formed using base and geodesic features 1510 and apex and geodesic features 1530. Each of the three pieces 1510,1520, 1530 includes an internal recessed surface (relative to the interior of the assembled base fitting 1510) that, when placed together, forms the slots 1501-1507.

Fig. 15B shows a top view of base fitting 1500. From this perspective, only the base and apex elements 1520 and the apex and geodesic elements 1530 are clearly visible. From this view, it will be understood by those of ordinary skill in the art that the base and apex elements 1520 include concave inner surfaces that form the slots 1502, 1506 and 1507. Apex and geodesic part 1530 includes concave inner surfaces that form slots 1501 and 1503 and 1507. The non-recessed portions of the two pieces 1520 and 1530 (e.g., the portion between the slots 1503 and 1507, the portion between the slots 1507 and 1506, and the portion between the slots 1506 and 1501) can abut to form a bonding surface.

Fig. 15C shows a bottom view of the base fitting 1500. From this perspective, only the base and geodesic piece 1510 are visible. It will be appreciated that the base and geodesic features 1510 may include internal recessed surfaces that form the slots 1501-1505. The non-recessed portions of the part 1510 (e.g., the portions between the troughs 1501 and 1502, the portions between the troughs 1502 and 1503, the portions between the troughs 1503 and 1504, the portions between the troughs 1504 and 1505, and the portions between the troughs 1505 and 1501) can abut the corresponding portions of the base and apex part 1520 and the apex and geodesic part 1530 to form a joining surface.

Fig. 15D shows a side view of base joint 1500 where base-to-base slot 1502 and base-to- apex slots 1506 and 1507 are positioned. From this view, the hollow interior of the base-to-base slot 1502 can be seen. The base and apex features 1520 are configured to abut the other two features. The base and apex elements 1520 include portions that are substantially in the same plane as the base and geodesic elements 1510, and together they form a base-to-base slot 1502. The base and apex element 1520 further includes a second portion that is angled from the base plane and this portion is configured to abut a portion of the apex and geodesic element 1530 to form base-to- apex slots 1506 and 1507.

Fig. 15E shows another side view of the base fitting 1500 opposite the view shown in fig. 15D. This angle shows a back/top view of base-to- geodesic slots 1504 and 1505, and base-to- apex slots 1506 and 1507. The apex and geodesic piece 1530 includes portions that are substantially in the same plane as the base and geodesic piece 1510, and together they form base-to- geodesic slots 1504 and 1505. The apex and geodesic piece 1530 also includes a second portion that is angled from the base plane and that is configured to abut the angled portion of the base and apex piece 1520 (not shown in FIG. 15E) to form base-to- apex slots 1506 and 1507.

Fig. 15F shows yet another side view of the base joint 1500 with the base-to-base channel 1503 positioned. The view on the opposite side from the base to the base where the slot 1501 is located is not shown because it is symmetrical to the view shown in fig. 15F. From this perspective, it can be seen that the hollow interior of the base-to-base channel 1503 extends through the body of the base fitting 1500. Thus, in the illustrated embodiment, the base-to-base slots 1503 and 1501 are opposite ends of the same slot. Thus, a connector can extend through this slot through the body of the base fitting 1500. In a particular embodiment, the base-to-base slot 1503 (and similarly 1502) may be formed by all three of the base and geodesic features 1510, the base and apex features 1520, and the apex and geodesic features 1530. The concave inner portions of the base and geodesic pieces 1510 form approximately half of the base-to-base slot 1503. The other half may be formed by the concave portions of the base and apex elements 1520 and the concave portions of the apex and geodesic elements 1530. Since the angle between slots 1507 and 1502 is relatively small compared to the angle between slots 1507 and 1504 in the illustrated embodiment, the concave portion of base and apex element 1520 is also relatively smaller than the concave portion of apex and geodesic element 1530.

Fig. 15G shows an exploded view of the base joint 1500. Each of the features (i.e., 1510,1520, and 1530) includes an interior concave surface for forming the above-described groove. In particular, the groove 1501 is formed by the inner concave surfaces 1501a, 1501b and 1501c of the parts 1510,1520 and 1530, respectively. The channel 1503 is formed by concave inner surfaces 1503a, 1503b and 1503c of parts 1510,1520 and 1530, respectively. The slot 1502 is formed by concave inner surfaces 1502a and 1502b of features 1510 and 1520, respectively. The slot 1504 is formed by the inner concave surfaces 1504a and 1504b of the features 1510 and 1530, respectively. The groove 1505 is formed by the concave inner surfaces 1505a and 1505b of parts 1510 and 1530, respectively. The channel 1506 is formed by concave inner surfaces 1506a and 1506b of the parts 1530 and 1520, respectively. The slot 1507 is formed by the concave inner surfaces 1507a and 1507b of the parts 1530 and 1520, respectively. As previously described, for each part, the portion between the concave surfaces forming the grooves may be substantially flat and configured to abut a corresponding portion of the other part. The surface area of the abutment surfaces is made large enough to strengthen the bond between the parts. In particular embodiments, adhesives such as liquid adhesives and/or conventional fasteners (e.g., nuts and bolts) may be used.

Fig. 16A-16B illustrate an embodiment of a mold for making the base and geodesic features 1510. In a particular embodiment, the mold assembly can include a male mold 1610 and a female mold 1620. One example of a mold is shown in fig. 16A. Two dies may be used to press against the carbon fiber twill placed between them to create the base and geodesic features 1510. The profile of the male mold 1610 may form the inner surface of the base and the geodetic part 1510, and the profile of the female mold 1620 may form the outer surface of the base and the geodetic part 1510. For example, FIG. 16B shows a side view of the same assembly shown in FIG. 16A. It will be appreciated that the protruding profile 1613a of the male die 1610 and the recessed profile 1623a of the female die 1620, when pressed together, will form the profile 1503a of the base and the ground wire part 1510. As another example, the protruding profile 1612a of the male die 1610 and the recessed profile 1622a of the female die 1620, when pressed together, will form the profile 1502a of the base and geodesic piece 1510. Similarly, the contours of other portions of part 1510 can be defined by corresponding portions of dies 1610 and 1620. For example, the concave profiles 1621a, 1624a, and 1625a of the female die 1620 may be pressed against corresponding protrusions (not shown) of the male die 1610 to form the profiles 1501a, 1504a, and 1505a of the base and geodesic piece 1510. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, molds 1610 and 1620 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or enhance the structure of the mold. For example, after the mold 1610 has been created, cement may be poured into it through the opening 1611 on the top, as shown in fig. 16A.

17A-17B illustrate an embodiment of a mold for making apex and geodesic part 1530. In a particular embodiment, the mold assembly can include a female mold 1710 and a male mold 1720. Fig. 17A to 17B show an example of a mold. Two dies may be used to press against the carbon fiber twill placed between them to create the apex and geodesic part 1530. The profile of the male mold 1720 may form the inner surface of the apex and geodesic part 1530 and the profile of the female mold 1710 may form the outer surface of the apex and geodesic part 1530. It will be appreciated that the protruding profiles 1725b and 1724b of the male die 1720 and the recessed profiles 1715b and 1714b of the female die 1710 will form profiles 1505b and 1504b, respectively, of the apex and geodesic part 1530 when pressed together. Similarly, the contours of other portions of part 1530 may be defined by corresponding portions of molds 1710 and 1720. For example, the protruding profiles 1726a and 1727a of the male die 1720 may be pressed against corresponding recessed profiles (not shown) of the female die 1710 to form the profiles 1506a and 1507a of the base and geodesic features 1510. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, molds 1710 and 1720 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or enhance the structure of the mold. For example, after the mold 1710 has been created, cement may be poured therein through the opening 1711 on the top.

Similar to the base and geodesic piece 1510 and the apex and geodesic piece 1530, the base and apex piece 1520 may be manufactured by pressing a male and female mold against a carbon fiber twill. The female mold may have a concave profile and the male mold may have a convex profile that when pressed together defines the profile of the base and apex pieces 1520.

Fig. 18A-18B illustrate an example of a 4-way geodesic connector having four connector slots, such as the connector 335 shown in fig. 3C and 3D. In a particular embodiment, the 4-way geodesic connector 335 is used to form a substantially flush geodesic structure in the same plane. Each 4-way geodesic connector 335 may be used as a junction of four connectors to form an "X" pattern, as shown in fig. 3C. To accommodate four connectors, the 4-way geodesic connector 335 may have four slots 1801, 1802, 1803, and 1804 configured symmetrically. The groove may be formed by the internal concave surfaces of top part 4010 and bottom part 4020. Fig. 18B shows an exploded view of the 4-way geodesic connector 335. Each of the top part 4010 and the bottom part 4020 has an internal recess surface that forms slots 1801 and 1804 when assembled. In particular, the concave inner faces 1801a, 1802a, 1803a and 1804a of the top part 4010 and the corresponding concave inner faces 1801b, 1802b, 1803b and 1804b of the bottom part 4020 may form slots 1801, 1802, 1803 and 1804, respectively. In certain embodiments, at the center of the 4-way geodesic connector 335 may be a 4-way plug 1830, which may facilitate and maintain placement of the inserted connector. In certain embodiments, similar to other processes described herein for making joints, the 4-way geodesic joint 335 may be made by sandwiching a carbon fiber twill between molds.

Fig. 19A-19B illustrate an example of a 6-way geodesic connector having six connector slots, such as the connector 330 shown in fig. 3C and 3D. In a particular embodiment, the 6-way geodesic connector 330 is used to form a substantially flush geodesic structure in the same plane. As shown in fig. 3C, in one embodiment, the geodesic structure may include an "X" pattern that is formed using the 4-way geodesic connector 335 described above. Each "X" structure may be positioned between two longitudinal connectors 290. The "X" configuration may be connected to the longitudinal connector 290 using a 6-way geodesic connector 330. Each 6-way ground wire connector 330 can have six connector slots 1901-1906. In particular embodiments, two connector slots 1901 and 1902 on opposite sides of joint 330 can form a passage through joint 330 to allow longitudinal connector 290 to pass through. The other four connector slots 1903-1906 of the 6-way geodesic contact 330 can be configured to connect to the four "X" patterns, respectively, to form a geodesic structure 295. For example, the lower right connector of the first "X" configuration may be connected to the slot 1905 of the 6-way ground contact 330; the lower left connector of the second "X" configuration may be connected to the slot 1906 of the fitting 330; the upper left connector of the third "X" configuration may be connected to the slot 1903 of the fitting 330; the upper right connector of the fourth "X" configuration may be connected to the slot 1904 of the header 330. Fig. 19B shows an exploded view of the 6-way geodesic connector 330. Each of the top part 1910 and the bottom part 1920 has an internal concave surface that, when assembled, forms the slots 1901-1906. In particular, the interior recessed faces 1901a, 1902a, 1903a, 1904a, 1905a, and 1906a of the top part 1910 and the corresponding interior recessed faces 1901b, 1902b, 1903b, 1904b, 1905b, and 1906b of the bottom part 1920 can form grooves 1901, 1902, 1903, 1904, 1905, and 1906, respectively. In certain embodiments, the 6-way geodesic joint 330 may be manufactured by sandwiching carbon fiber twill cloth between molds, similar to other processes described herein for manufacturing joints.

In certain embodiments, if additional slots are required to attach the connector to the apex or base joint as described above, the peripheral component may be attached to the joint to form the required slots. In particular embodiments, the peripheral component may be considered a wrap or glove that fits over the assembled apex or base joint. The contour of the peripheral component together with the outer surface of the apex or base joint may form an additional slot for receiving a connector. The peripheral component may be secured to the joint using, for example, adhesive, screws, or other attachment means. In a particular embodiment, the peripheral component can be manufactured using a mold, similar to the process described above. In the above examples for manufacturing joints (vertices or bases) of e.g. a main frame, three dies may be used: an outer female mold, a central mold, and an outer male mold. To manufacture additional peripheral components, a fourth mold may be added to separately sandwich three layers of carbon fiber twill cloth to form the female half of the joint, the male half of the joint, and the peripheral components of the joint, respectively. In certain embodiments, the fourth mold may be configured to fit on top of the outer female mold, which will become the second central mold. In such a configuration, the top portion of the second central mold may be configured to define a desired interior profile of the peripheral component, and the fourth mold may be configured to define a desired exterior profile of the peripheral component. Alternatively, the peripheral component may be manufactured using a separate mold.

Fig. 20A-20B illustrate embodiments of peripherally extending slots for the apex joints of a pyramid structure (e.g., 305 shown in fig. 5A) of a master frame from different perspectives. In a particular embodiment, the extension joint 2000 may be fixed to the apex joint 305 of the intersecting main frame pyramid structure such that it may be connected to the apex joint of an adjacent intersecting ramp pyramid structure, as shown at 349 in fig. 3D. In a particular embodiment, the extension joint 2000 may have two pieces, referred to herein as a top piece 2010 and a bottom piece 2020. The top piece 2010 and the bottom piece 2020 may be configured to enclose a portion of the outer surface of the female half 501 of the apex joint 305 and further form a slot 2030 for receiving a connector. In a particular embodiment, the slot 2030 may be substantially perpendicular to the apex-to-apex slot of the apex joint 305. One end of top part 2010 may have an extension 2011 configured to form half of slot 2030 and surrounding material for interfacing with bottom part 2020. The remainder of the top piece 2010 may surround a portion of the exterior of the apex joint 305. The bottom part 2020 similarly may have an extension 2021 configured to form the other half of the slot 2030, and surrounding material for interfacing with the surrounding material of the extension 2011 of the top part 2010. The remainder of the base section 2020 may surround a portion of the exterior of the apex joint 305. In particular embodiments, adhesive may be used to bond the top part 2010 and the bottom part 2020 to the apex joint 305 and to each other. In certain embodiments, the top part 2010 and the bottom part 2020 of the extension joint 2000 may be manufactured using a 3D printed mold and pressing it against the carbon fiber material, similar to the manufacturing process described above for the joint.

Fig. 21 shows an exploded view of the extension joint 2000 shown in fig. 20A-20B without the apex joint 305 of the pyramid structure of the main frame. Extensions 2011 and 2021 of top part 2010 and bottom part 2020, respectively, are configured to be placed together to form slot 2030. In addition to the extensions 2011 and 2021, the remainder of the top part 2010 and the bottom part 2020 may be configured to encompass portions of the apex joint 305 of the pyramid structure of the master frame. For example, the top part 2010 may have concave inner surfaces 2191 and 2192 that match the contour of the outer surface of the top of the female half 501, e.g., of the apex joint 305. As another example, the top part 2010 may have internal concave surfaces 2112 and 2113 that match the profile of the outer surfaces of the apex-to- base slots 513 and 514, respectively, of the apex joint 305, for example. Similarly, the bottom part 2020 may have inner concave surfaces 2122 and 2123 that match the profile of the outer surfaces of the apex-to-base grooves (not shown in fig. 5A), e.g., on opposite sides of the grooves 513 and 514.

Fig. 22A-22B illustrate an embodiment of a mold for manufacturing the top part 2010 of the extension joint 2000. In a particular embodiment, the mold assembly may include a female mold 2210 and a male mold 2220. One example of a mold is shown in fig. 22A. Two dies may be used to press the carbon fiber twill cloth placed between them to create the top part 2010 of the extension joint 2000. The profile of the male tooling 2220 may form the inner surface of the top part 2010 and the profile of the female tooling 2210 may form the outer surface of the top part 2010. For example, the convex profiles 2291, 2292, and 2211 of the male mold 2220 may shape the concave inner surfaces 2191, 2192, and 2011, respectively, of the top part 2010. Fig. 22B shows a side view of the same assembly shown in fig. 22A. It will be appreciated that the protruding male profile 2292 of the male die 2220 and the female profile 228 of the female die 2210, when pressed together, will form the profile 2192 of the top part 2010. Similarly, the contours of other portions of the top part 2010 may be defined by corresponding portions of the dies 2210 and 2220. For example, the protruding male profile 2295 of the male die 2220 and the female profile 2285 of the female die 2210, when pressed together, will form the profile 2112 of the top part 2010. Although not shown, female die 2210 has a concave profile that corresponds to the placement of the protruding convex profile 2211 of male die 2220, such that when pressed together will define the profile 2011 of top part 2010. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, the molds 2210 and 2220 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or enhance the structure of the mold. For example, cement may be poured into the mold through the opening after the mold has been created.

Fig. 23 shows a perspective view of an embodiment of a male mold for making the top part 2010 of the extension joint 2000. The male tool 2220 may have protruding convex surfaces 2211, 2292, and 2295 as described above. As shown here, the male mold 2220 may be symmetric about a central plane that passes through the axis of the projection surface 2211.

In a particular embodiment, as shown in fig. 3D, the internal base joint of the intersecting main frame pyramid structure 340 may need to be shared with the base joints of the intersecting ramp pyramid structure 343 and geodesic structure. In order to also serve as the base joint of the intersecting ramp pyramid structure 343, the base joint 359 of the intersecting main frame pyramid structure 340 may require two additional slots. The slots may be used to connect each base joint 359 to the apex joint 375 and one other base joint 1500 of the intersecting ramp pyramid structure 343. In the particular embodiment where the geodesic structure is connected to the main frame and gangway as shown in fig. 3D, the base connector 359 of the intersecting main frame pyramid structure 340 may require an additional slot to connect to one end of the X-pattern geodesic structure (in other words, the base connector 359 would connect to the 4-way geodesic connector 335 of the X-pattern). Thus, in one embodiment, the internal base joint 359 of the intersecting main frame pyramid structure 340 may require three additional slots to support the intersecting ramp pyramid structure 343 and geodesic structure.

Fig. 24A-24C show an embodiment of a main frame to ramp and geodesic extension 2400 attached to the base joint 301 of the main frame, similar to the internal base joint 359 shown in fig. 3D. The main frame to ramp and geodesic extension 2400 shown includes three parts, which will be referred to as a base part 2410, a center part 2420 and a vertex part 2430. In addition to the slots provided by the base tabs 301, the extension tabs 2400 add three additional slots: slots 2440 and 2460 for connection to the intersecting ramp pyramid structure 343, and slot 2450 for connection to the geodesic structure. In particular, the slot 2440 may be configured to receive a connector whose other end is connected to the internal base joint 1500 (see fig. 3D) of the adjoining intersecting ramp pyramid structure 343 (i.e., not interfacing with the main frame). The connectors are substantially perpendicular to the main frame and form one side of the base of the intersecting ramp pyramid structure 343. The slot 2460 can be configured to receive a connector whose other end is connected to the apex 375 of the intersecting ramp pyramid structure 343. The slot 2450 can be configured to receive a connector, the other end of which is connected to a 4-way geodesic connector 335, through which the above-described "X" pattern can be formed. In addition, fig. 24A shows the position where a plug 2490 can be placed within the base fitting 301 to guide and retain an inserted connector.

In a particular embodiment, each of slots 2440, 2450, and 2460 can be formed from two of the three parts 2410, 2420, and 2430. For example, slots 2440 and 2450 may be formed by the inner concave surfaces of base part 2410 and center part 2420. The slot 2460 may be formed by the concave inner surfaces of the center part 2420 and the apex part 2430. In particular, base part 2410 may have concave inner surfaces 2413 and 2411 that, when aligned with corresponding concave inner surfaces 2423 and 2421, respectively, of central part 2420, will form grooves 2450 and 2440, respectively. Another concave surface 2422 of the center part 2420 may align with a concave surface 2431 of the apex part 2430 to form a slot 2460. Each of the components 2410, 2420, and 2430 can have a portion that abuts a corresponding portion of an adjacent component. The surface area of these portions may be used to fasten each pair of abutments together (e.g., using adhesives, nuts and bolts, etc.).

Each of parts 2410, 2420 and 2430 includes an additional remaining portion for surrounding a portion of the exterior of base sub 301, in addition to the portion of each part 2410, 2420 and 2430 that forms grooves 2440, 2450 and 2460 and that abut each other. For example, the apex feature 2430 may have portions configured to surround the outer surfaces of the channels 913 and 915 (see fig. 9A) and the surrounding surface of the base fitting 301. The base part 2410 may have a portion configured to surround the outer surface of the groove 911 and the surrounding surface of the base fitting 301. The center part 2420 may include an enclosure portion that conforms to the contour of the top of the base joint 301 not occupied by the apex part 2430 and the base part 2410. In a particular embodiment, an adhesive may be used to bond the three parts 2410, 2420 and 2430 to the base joint 301 and to each other.

Figure 25 shows an exploded view of a main frame to ramp and geodesic extension 2400 for a base joint 301 (not shown) of the main frame. As discussed with reference to fig. 24A-24C, the main frame to ramp piece and geodesic extension 2400 may have three parts: base part 2410, center part 2420, and apex part 2430. In a particular embodiment, each of these parts is a continuous part made of carbon fiber twill sheet. The base part 2410 may include concave inner faces 2411 and 2413 for forming grooves 2440 and 2450, respectively. Additionally, base part 2410 may also include a surface for engaging center part 2420. In particular, surfaces 2511, 2512, and 2513 of base part 2410 are configured to abut corresponding surfaces 2521, 2522, and 2523, respectively, of central part 2420. Base part 2410 may also include a surface 2514 for enclosing the top portion of base sub 301. The inner concave surface 2515 may be configured to surround a portion of the outer surface of the slot 911 of the base sub 301. The central part 2420 may comprise a surface, such as surface 2424, for enclosing another top portion of the base fitting 301. To couple to the apex part 2430, the central part 2420 may also include a surface, such as surface 2526, to abut surface 2536 of the apex part 2430. The apex surface 2430 may include surfaces 2531, 2532, and 2533 for encircling the outer surface of the base joint 301 about the grooves 913 and 915. The apex surface 2430 may also include surfaces 2534 and 2535 for surrounding the outer surfaces of the grooves 913 and 915, respectively.

Fig. 26A-26B show top and bottom views, respectively, of the apex feature 2430. The top surface shown in fig. 26A is considered to be the inner portion as it will form the inner surface of the assembled main frame to extension 2400 of the gangway and geodesic. Referring to fig. 26A and 26B, the bottom portion of the apex element 2430 has an inner surface 2601a and a corresponding outer surface 2601B. Similarly, apex feature 2430 also includes: an inner surface 2602a and a corresponding outer surface 2602b (corresponding to portion 2431 in fig. 25); inner surface 2603a and corresponding outer surface 2603b (corresponding to portion 2536); inner surface 2604a and corresponding outer surface 2604b (corresponding to portion 2532); inner surface 2605a and corresponding outer surface 2605b (corresponding to portion 2535); inner surface 2606a and corresponding outer surface 2606b (corresponding to portion 2531); and an inner surface 2607a and a corresponding outer surface 2607b (corresponding to portion 2534). Once assembled, the top surface 2602a will abut connectors connected to intersecting ramp pyramid structures. Top surfaces 2605a and 2607a will abut and be secured to outer surfaces 915 and 913, respectively.

27A-27B illustrate an embodiment of a mold for making the apex part 2430. In a particular embodiment, the mold assembly can include a male mold 2710 and a female mold 2720. One example of a mold is shown in fig. 27A. Two dies may be used to press the carbon fiber twill cloth placed between them to create the apex feature 2430. The profile of the male mold 2710 may form the inner surface of the apex feature 2430 and the profile of the female mold 2720 may form the outer surface of the apex feature 2430. For example, FIG. 27A shows that the protruding contours 2702 of the male mold 2710 can form contours 2607A/2607b of the apex feature 2430. Fig. 27B shows a side view of the same assembly shown in fig. 27A. It will be appreciated that the protruding profile 2701 of the male mold 2710 and the recessed profile 2711 of the female mold 2720, when pressed together, will form the profiles 2602a/2602b of the apex part 2430. Similarly, the contours of other portions of part 2430 can be defined by corresponding portions of dies 2710 and 2720. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, the molds 2710 and 2720 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or enhance the structure of the mold. For example, cement may be poured into the mold through the opening after the mold has been created.

Fig. 28A-28B show top and bottom views, respectively, of the central part 2420. The top surface shown in fig. 28A is considered to be the inner portion as it will form the inner surface of the assembled main frame to extension 2400 of the gangway and geodesic. Referring to fig. 28A and 28B, the center part 2420 includes: an inner surface 2801a and a corresponding outer surface 2801b (corresponding to portion 2421 in fig. 25); inner surface 2802a and corresponding outer surface 2802b (corresponding to portion 2521); an inner surface 2803a and a corresponding outer surface 2803b (corresponding to portion 2422); inner surface 2804a and corresponding outer surface 2804b (corresponding to portion 2526); inner surface 2805a and corresponding outer surface 2805b (corresponding to portion 2524); inner surface 2806a and corresponding outer surface 2806b (corresponding to portion 2523); an inner surface 2807a and a corresponding outer surface 2807b (corresponding to portion 2423); and an inner surface 2808a and a corresponding outer surface 2808b (corresponding to portion 2522). Once assembled, the top surface 2803a will abut a connector, the other end of which is connected to the apex 375 of the intersecting ramp pyramid structure 343, as shown in fig. 3D. The top surface 2801a will abut a connector whose other end is connected to the inner base joint 1500 of the adjoining intersecting ramp pyramid structure 343. The top surface 2807a will abut the connector, the other end of which is connected to the 4-way geodesic connector 335, through which the "X" pattern described above can be formed.

Fig. 29A-29B illustrate an embodiment of a mold for making the central part 2420. In a particular embodiment, the mold assembly can include a male mold 2910 and a female mold 2920. One example of a mold is shown in fig. 29A. Two dies may be used to press the carbon fiber twill cloth placed between them to create the center part 2420. The profile of the male mold 2910 may form the inner surface of the central part 2420 and the profile of the female mold 2920 may form the outer surface of the central part 2420. For example, the protruding ledge 2901 of the male mold 2910 shown in fig. 29A is configured to form the concave inner surface 2803a of the central part 2420. Similarly, the protruding projections 2902 and 2903 of the male mold 2910 are configured to form inner surfaces 2801a and 2807a, respectively, that are on opposite sides of the outer surfaces 2801b and 2807b, respectively. Fig. 29B shows a side view of the same assembly shown in fig. 29A. It should be understood that the protruding profiles 2902 and 2903 of the male mold 2910 will form the recessed profiles 2801b and 2807b, respectively, of the central part 2420. Similarly, the contours of other portions of the central part 2420 can be defined by corresponding portions of the molds 2910 and 2920. For example, the substantially planar surface 2804a of the central part 2420 can be formed by a surface 2932 of the female mold 2920 and a corresponding surface (not shown) of the male mold 2910. The backside of surface 2803a will be formed by concave profile 2931 of female mold 2920. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, molds 2910 and 2920 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or enhance the structure of the mold. For example, cement may be poured into the mold through the opening after the mold has been created.

Fig. 30A-30B show top and bottom views, respectively, of the base part 2410 with some variation. The top surface shown in fig. 30A is considered internal as it may form the inner surface of the assembled main frame to ramp piece and geodesic extension 2400. Referring to fig. 30A and 30B, the base part 2410 includes: an inner surface 3001a and a corresponding outer surface 3001b (similar to portion 2515 in FIG. 25); an inner surface 3002a and a corresponding outer surface 3002b (corresponding to portion 2514); an inner surface 3003a and a corresponding outer surface 3003b (corresponding to portion 2513); an inner surface 3004a and a corresponding outer surface 3004b (corresponding to portion 2413); an inner surface 3005a and a corresponding outer surface 3005b (corresponding to portion 2512); an inner surface 3006a and a corresponding outer surface 3006b (corresponding to portion 2411); and an inner surface 3007a and a corresponding outer surface 3007b (corresponding to portion 2511). Once assembled, the top surface 3006a will abut a connector, the other end of which is connected to the internal base joint of the adjoining intersecting ramp pyramid structure (i.e., not interfacing with the main frame). The top surface 3004a may abut a connector, the other end of which is connected to a 4-way geodesic connector 335, through which the above-described "X" pattern may be formed. The top surfaces 3001a and 3002a will abut and be secured to the outer surface of the female half 901 of the base fitting 301.

Fig. 31A-31B illustrate an embodiment of a mold for making the base part 2410. In a particular embodiment, the mold assembly may include a male mold 3110 and a female mold 3120. One example of a mold is shown in fig. 31A. Two dies may be used to press the carbon fiber twill cloth placed between them to create base part 2410. The contour of the male mold 3110 may form an inner surface of the base part 2410, and the contour of the female mold 3120 may form an outer surface of the base part 2410. For example, the protruding male portion 3102 of the male mold 3110 shown in fig. 31A is configured to form an inner concave surface 3006a of the base part 2410, and the female portion 3104 of the female mold 3120 is configured to form an outer surface 3006b of the base part 2410. Similarly, the protruding male portion 3101 of the male mold 3110 and the female portion 3103 of the female mold 3120 are configured to form an inner surface 3004a and a corresponding outer surface 3004b, respectively, of the base part 2410. Fig. 31B shows a perspective view of the same assembly shown in fig. 31A. It will be appreciated that the protruding concave surface 3001a and corresponding back surface 3001b are formed by pressing together the convex portion 3105 of the male mold 3110 and the concave portion 3106 of the female mold 3120. Similarly, the concave surface 3002a of the base part 2410 and its corresponding back side are formed by pressing together the convex portion 3102 of the male mold 3110 and the concave portion 3104 of the female mold 3120. The concave surface 3004a of the base part 2410 and its corresponding back side are formed by pressing together the convex portion 3101 of the male mold 3110 and the concave portion 3103 of the female mold 3120. The other portions of the base part 2410 are similarly formed. For example, substantially planar surfaces 3003a, 3005a, and 3007a and their corresponding backsides are formed by substantially planar portions of a mold, such as 3143, 3145, and 3147 of female mold 3120. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, the molds 3110 and 3120 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or enhance the structure of the mold. For example, after the mold has been created, cement may be poured through the opening into it, such as the hole 3151 and 3154 of the male mold 3110.

Fig. 32 shows an exploded view of an embodiment of a main frame to geodesic extension 3200 configured to be attached to a base joint 301 of the main frame. The particular embodiment of the joint 339 shown in fig. 3C and 3D may be assembled in this manner using a main frame to geodesic extension 3200. In a particular embodiment, the base joint 301 of the main frame may be the base joint interfacing with a geodesic structure rather than a gangway. The main frame to geodesic extension 3200 is shown to comprise two parts, referred to as a top part 3210 and a bottom part 3220. When assembled, the top part 3210 and the bottom part 3220 form three additional extension slots for connecting the base sub 301 to the geodetic structure. One of the three extension slots (referred to as a longitudinal slot) may be configured to receive a connector, the other end of which is connected to a 6-way ground pin 330 (see fig. 3C). The connector may be substantially perpendicular to the main frame and may form a common boundary between the two "X" patterns of the geodesic structure. These two "X" patterns may be referred to as a top "X" pattern and a bottom "X" pattern, respectively, and each of the "X" patterns may have a corresponding 4-way geodesic connector 335 at the center. The remaining two of the three extension grooves of the main frame to geodesic extension 3200 may be configured to be connected to the top "X" pattern and the bottom "X" pattern, respectively. In particular, one of the extension slots may be configured to receive a connector having another end connected to the 4-way geodetic contact 335 of the top "X" pattern, and the other extension slot may be configured to receive a connector having another end connected to the 4-way geodetic contact 335 of the bottom "X" pattern.

In a particular embodiment, once assembled, each extension slot of the main frame to geodesic extension 3200 may be formed by a top part 3210 and a bottom part 3220. For example, the longitudinal grooves for connection to a 6-way geodesic connector may be formed by the inner concave surfaces 3242 and 3252 of the top and bottom parts 3210 and 3220, respectively. One of the grooves for connecting to the 4-way geodesic connector may be formed by the inner concave surfaces 3243 and 3253 of the top and bottom parts 3210 and 3220, respectively. Another groove for connecting to another 4-way geodesic connector may be formed by the inner concave surfaces 3241 and 3251 of the top part 3210 and the bottom part 3220, respectively. In particular embodiments, top section 3210 may have portions that abut corresponding portions of bottom section 3220, such as substantially flat surfaces between concave inner surfaces. The surface area of these portions may be used to bond top part 3210 and bottom part 3220 together (e.g., using adhesives, nuts and bolts, etc.).

In addition to the portions used to create the extension slots, the top and bottom parts 3210 and 3220 include additional portions for enclosing the exterior of the base fitting 301. For example, the top piece 3210 may have inner concave surfaces 3244 and 3245 configured to surround the outer surfaces of the grooves 915 and 913 (see fig. 9A) of the base fitting 301, respectively. The bottom part 3220 may have an inner concave surface 3254 configured to surround the outer surface of the slot 911 and the surrounding surface of the base sub 301. The bottom section 3220 may also have inner concave surfaces 3255 and 3256 configured to surround the outer surfaces of the grooves 912 and 914 of the base sub 301. In certain embodiments, an adhesive may be used to bond the top and bottom parts 3210 and 3220 of the main frame to geodesic extension 3200 to the base joint 301 and to each other.

Fig. 33A-33B show top and bottom views, respectively, of top part 3210. The top surface shown in fig. 33A is considered to be the inner portion as it will form the inner surface of the assembled main frame to geodesic extension 3200. Referring to fig. 33A and 33B, top part 3210 includes: an inner surface 3341a and a corresponding outer surface 3341b (corresponding to portion 3243 in fig. 32); an inner surface 3342a and a corresponding outer surface 3342b (corresponding to portion 3242); an inner surface 3343a and a corresponding outer surface 3343b (corresponding to portion 3231); an inner surface 3344a and a corresponding outer surface 3344b (corresponding to portion 3245); and an inner surface 3345a and a corresponding outer surface 3345B (corresponding to portion 3244). The top part 3210 also includes interior surfaces 3361a, 3362a, 3363a, 3364a, and 3365a and corresponding exterior surfaces 3361b, 3362b, 3363b, 3364b, and 3365b, respectively. Once assembled, the inner surfaces 3241, 3242 and 3243 will abut connectors connected to adjacent geodesic structures. For example, the inner surfaces 3361a, 3362a, 3363a and 3364a of the top part 3210 will abut corresponding inner surfaces of the bottom part 3220, as will be described with reference to fig. 35A-35B. The inner surfaces 3344a, 3345a, and 3365a will abut and be secured to the outer surfaces of the grooves 913, 915, respectively, and the portion therebetween.

Fig. 34A-34B illustrate an embodiment of a mold for making top part 3210. In a particular embodiment, the mold assembly may include female mold 3410 and male mold 3420. One example of a mold is shown in fig. 34A. Two dies may be used to press the carbon fiber twill cloth placed between them to create top part 3210. The contour of male tooling 3420 may form the inner surface of top part 3210 and the contour of female tooling 3410 may form the outer surface of top part 3210. For example, concave profile 3411 of female mold 3410 and convex profile 3421 of male mold 3420, when pressed together, may form concave portion 3241 of top part 3210. Similarly, concave profile 3415 of female mold 3410 and convex profile 3425 of male mold 3420, when pressed together, may form concave portion 3245 of top part 3210. Although not shown, it should be understood that additional concave profiles of female mold 3410 corresponding to convex profiles 3422, 3423, and 3424 of male mold 3420, when pressed together, may form concave portions 3242, 3243, and 3244 of top part 3210. FIG. 34B shows a side view of the same assembly shown in FIG. 34A. It will be appreciated that the projecting male profiles 3421, 3422 and 3423 of male die 3420 and the corresponding female profiles 3411, 3412 and 3413 of female die 3410, when pressed together, will form female portions 3241, 3242 and 3243, respectively, of top part 3210. Similarly, although not shown, female mold 3410 female profile and corresponding male profiles 3424 and 3425 may form female portions 3244 and 3245, respectively, of top part 3210 when pressed together. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, the molds 3410 and 3420 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or enhance the structure of the mold. For example, after the mold has been created, cement may be poured therein through openings 3431, 3432, 3433, and 3434 such as female mold 3410.

Fig. 35A-35B show top and bottom views, respectively, of bottom section 3220. The top surface shown in fig. 35A is considered to be the inner portion as it will form the inner surface of the assembled main frame to geodesic extension 3200. Referring to fig. 35A and 35B, the top part 3220 includes: an inner surface 3551a and a corresponding outer surface 3551b (corresponding to portion 3251 in fig. 32); an inner surface 3552a and a corresponding outer surface 3552b (corresponding to portion 3252); an inner surface 3553a and a corresponding outer surface 3553b (corresponding to portion 3253); an inner surface 3554a and a corresponding outer surface 3554b (corresponding to portion 3254); an inner surface 3555a and a corresponding outer surface 3555b (corresponding to portion 3255); and an inner surface 3556a and a corresponding outer surface 3556b (corresponding to portion 3256). Bottom section 3220 also includes inner surfaces 3571a, 3572a, 3573a, and 3574a and corresponding outer surfaces 3571b, 3572b, 3573b, and 3574 b. Once assembled, the inner surfaces 3551a, 3552a, and 3553a will abut connectors connected to adjacent geodesic structures. The inner surfaces 3571a, 3572a, 3573a and 3574a of the bottom piece 3220 will abut the corresponding inner surfaces 3364a, 3363a, 3362a and 3361a of the top piece 3210. The inner surfaces 3555a, 3556a and 3554a will abut and be secured to the outer surfaces of the grooves 912, 914 and 911, respectively, of the base sub 301 of the main frame.

Fig. 36A-36B illustrate an embodiment of a mold for making the bottom part 3220. In a particular embodiment, the mold assembly can include a female mold 3620 and a male mold 3610. One example of a mold is shown in fig. 34A. Two dies may be used to press the carbon fiber twill cloth placed between them to create the bottom part 3220. The profile of the male die 3610 can form the inner surface of the bottom part 3220 and the profile of the female die 3620 can form the outer surface of the bottom part 3220. For example, the concave profiles 3672, 3673, 3676 of the female mold 3620 and the convex profiles 3652, 3653, 3656 of the male mold 3610, when pressed together, can form the concave portions 3252, 3253, 3256 of the bottom part 3220. Although not shown, it is understood that additional concave profiles of female mold 3620 corresponding to convex profiles 3651, 3655, and 3654 of male mold 3610, when pressed together, can form concave portions 3251, 3255, and 3254 of bottom part 3220. Fig. 36B shows a side view of the same assembly shown in fig. 36A. It will be appreciated that the protruding convex profiles 3651, 3652 and 3653 of the male die 3610 and the corresponding concave profiles 3671, 3672 and 3673 of the female die 3620, when pressed together, will form the concave portions 3251, 3252 and 3253 of the bottom part 3220, respectively. To improve the 3D printing time and structural integrity of the mold, in particular embodiments, molds 3610 and 3620 may be made hollow during the 3D printing process and subsequently filled with, for example, cement or any other suitable material that may cure or enhance the structure of the mold. For example, after the mold has been created, cement may be poured into it through openings 3661, 3662, 3663, and 3664, such as female mold 3620.

Fig. 37A illustrates an example structure 3700 of a rigid airship according to particular embodiments. Structure 3700 may include a hull section 3701, a bow section 3702, and a stern section 3703 to which the rudder of an airship may be attached. The structure 3700 can include a plurality of primary transverse or primary frames 3740. In a particular embodiment, each main frame 3740 is circular. In a particular embodiment, the main frames 3740 may be interconnected using longitudinal gangway 3704. In particular embodiments, wires connecting points on the inner circumference of each main frame 3740 (e.g., which may be constructed using Vectran fibers or any other suitable material having suitable strength and flexibility characteristics) may physically divide hull 3701 into multiple segments. These segments can be used to hold separate bladders containing a lift gas (e.g., helium).

Fig. 37B illustrates one embodiment of a main frame 3740. The main frame 3740 may include an outer portion 3710 and an inner portion 3720. In a particular embodiment, the main frame 3740 may be constructed using a pyramid structure 3750. Each pyramid structure 3750 can have a base and an apex. In certain embodiments, the pyramid structure 3750 can be configured such that its apex points toward the center of the main frame 3740 and its base faces outward. In this configuration, the outer portion 3710 of the main frame 3740 is formed by the connectors that form the base of the pyramid structures 3750, and the inner portion 3720 of the main frame 3740 is formed by the connectors that connect the vertices 3770 of those pyramid structures 3750. In certain embodiments, the base of the pyramid structure 3750 can include diagonal connectors 3780 and 3790, which can pass diagonally through the base in an alternating zigzag pattern.

Fig. 38 shows an example perspective view of a portion of the main frame 3740. In a particular embodiment, each pyramid structure (e.g., 3750a and 3750b) used to construct the master frame 3740 may have four base joints (e.g., 5200, 4100, 4800, and 4600) that form the base of the pyramid (e.g., 3750a) and a vertex joint (e.g., 4005a) that forms the vertex of the pyramid. In a particular embodiment, connectors or rods may connect the joints to form the pyramid structure 3750. For example, the base of pyramid 3750a may be formed by connector 3811 connecting base joints 5200 and 4100, connector 3812 connecting base joints 4100 and 4800, connector 3813 connecting base joints 4800 and 4600, connector 3814 connecting base joints 4600 and 5200, and diagonal connector 3790 connecting base joints 4100 and 4600. The sides of the pyramid 3750a may be formed by connectors 3815, 3816, 3817, and 3818 that connect the apex joint 4005a to the base joints 5200, 4100, 4800, and 4600, respectively. As another example, the base of the pyramid 3750b may be formed by a connector 3861 connecting the base joints 5100 and 5200, a connector 3814 connecting the base joints 5200 and 4600, a connector 3863 connecting the base joints 4600 and 4500, a connector 3862 connecting the base joints 4500 and 5100, and a diagonal connector 3780 connecting the base joints 5100 and 4600. The sides of the pyramid 3750b may be formed by connectors 3865, 3866, 3867, and 3868 that connect the apex joint 4900 to the base joints 5200, 5100, 4500, and 4600, respectively. In a particular embodiment, the main frame 3740 may be constructed using adjacent pyramid structures 3750. For example, between two adjacent pyramids 3750a and 3750b, one connector (e.g., 3814) may be shared between the bases of the two pyramids 3750a and 3750 b. In such a configuration, two adjacent pyramids may share one base connector and two corresponding base joints. For example, fig. 38 shows the base joints 5200 and 4600 and their connectors 3814 shared by two marked pyramids 3750a and 3750 b. In a particular embodiment, the vertex connectors (e.g., 4005a and 4900) of adjacent pyramids (e.g., 3750a and 3750b, respectively) may be connected by a vertex connector 3820. In a particular embodiment, the structural pattern of interconnected pyramid structures 3750 described above is repeated throughout the main frame 3740. In particular embodiments, the joints may be configured to create a circular main frame 3740. For example, the vertex joint 4005 may be configured such that its slots for receiving the vertex-to- vertex connectors 3820 and 3821 may be angled relative to each other to form an angle that approximates the polygon of the interior of the circular main frame 140. Similarly, each base joint (e.g., 5200) can be configured such that its two slots for receiving base connectors (e.g., 3811 and 3861) that form respective sides of adjacent pyramids (e.g., 3750a and 3750b) can be angled relative to each other to form an angle that approximates the polygon of the exterior of the circular main frame 3740. For example, base joint 5200 may be configured such that connectors 3811 and 3861 form corners of a 36-sided polygon. Further details of the construction of the joint are provided below.

Fig. 39A shows an example top view of a portion of an alternative geodesic structure 3999. As discussed above with reference to fig. 2B, the mainframe 140 may be connected by longitudinal connectors 290. Similarly, the main frame 3740 (e.g., as shown in fig. 37B) may be connected by longitudinal connectors 3990 in a geodesic structure 3999 shown in fig. 39A. In a particular embodiment, the two base tabs of the main frame 3740 may be connected by a single longitudinal connector 3990 that extends through a series of geodesic tabs (e.g., the 6-way geodesic tab 4400). In certain embodiments, the 6-way ground wire joint 4400 may have six connector notches. Two slots on opposite sides of the tab 4400 may form a channel through which the longitudinal connector 3990 may pass. The other four connector slots of the 6-way ground wire joint 4400 can be configured to connect to the other four 6-way ground wire joints 4400 to form a ground wire structure. In an alternative embodiment, two base tabs may be connected by a series of longitudinal connectors 3990 connected by a 6-way geodesic tab 4400 to form a substantially straight line.

Fig. 39B illustrates an embodiment of a portion of the hull structure, which is an alternative to the hull structure shown in fig. 3D. Fig. 39B shows a main frame 3740 (not labeled in fig. 39B for clarity but formed in part by pyramid structures 3943 and 3944) intersecting the gangway (not labeled in fig. 39B for clarity but formed in part by pyramid structures 3750a, 3750B, and 3750 c). Referring back to fig. 2B, two main frames 3740 may be connected by one or more gangway pieces. In a particular embodiment, both the main frame 3740 and the gangway may be constructed using a pyramid structure. Thus, at the intersection between the main frame 3740 and the gangway, the pyramid structure of the main frame 3740 (hereinafter referred to as the "intersecting main frame pyramid structure") may require additional slots to connect to or support the pyramid structure of the gangway (hereinafter referred to as the "intersecting gangway pyramid structure"). For example, fig. 39B illustrates that the intersecting main frame pyramid structure 3750B may be adjacent to three pyramid structures: two main frame pyramid structures 3750a and 3750c and one intersecting gangway pyramid structure 3943. In a particular embodiment, the apex 4900 of the intersecting main frame pyramid structure 3750b may have additional connector slots for connecting to the apex of the intersecting ramp pyramid structure 3943. In a particular embodiment, the interior base joint 4600 of the intersecting main frame pyramid structure 3750B may have additional connector slots, in addition to the slots for connecting to the adjoining corner cone structures (e.g., 3750B and 3750a) of the main frame, to connect to (1) the apex 4275 of the intersecting ramp pyramid structure 3943, (2) the base joint 4300 of the intersecting ramp pyramid structure 3943, (3) the 6-way geodesic joint 4400a, and (4) the ramp base 6-way geodesic joint 4400B forming part of the base of the intersecting ramp pyramid structure 3943. In a particular embodiment, the interior base joint 4500 of the intersecting main frame pyramid structure 3750b may have additional connector slots, in addition to the slots for connecting to the adjoining corner cone structures (e.g., 3750b and 3750c) of the main frame, to connect to (1) the apex 4275 of the intersecting ramp pyramid structure 3943, and (2) the ramp base 6-to-geodesic joint 4400b forming a portion of the base of the intersecting ramp pyramid structure 3943. In the embodiment shown in fig. 39B, each ramp pyramid structure (e.g., 3943 and 3944) has a base constructed using four corner base joints (e.g., 4300, 4600, 4500, and 4700) and the ramp base 6 to geodesic joints (e.g., 4400B) connected in the manner shown.

In particular embodiments, all joints described or otherwise indicated in this application for use in airship construction may be made of metal, including steel or titanium. Joints, including joints constructed using metal, may be made from lengths of tubing joined together by adhesive, welding, or any other method for joining the tubes. As one example, lengths of steel or titanium tubing may be fishmouth cut so that the tubing may be joined together without any gaps and without bending the tubing. In certain embodiments, a fitting made of metal may be attached to the carbon fiber connector using an adhesive. In certain embodiments, a length of tubing on a metal fitting may be connected with several carbon fiber connectors (in certain embodiments, the connectors may also be made of metal). In certain embodiments, the metal fitting may be connected to the carbon fiber connector by fitting a tubular metal segment of the fitting outside of the carbon fiber connector and injecting an adhesive into the space between the fitting and the connector. In other embodiments, the metal fitting may be connected to the carbon fiber connector by fitting a tubular metal segment of the fitting inside the tubular carbon fiber connector and injecting an adhesive into the space between the fitting and the connector. In certain embodiments, a collar may be used to help inject adhesive into the space between the fitting and the connector. In particular embodiments, the collar may be 3D printed from resin or any other suitable material, and may consist of an internal stepped structure, such that the collar may fit tightly around both the carbon fiber connector and the metal fitting, whichever is larger, and when the adhesive is injected and dries, hardens, the collar may hold the fitting and connector in place.

Fig. 40A (perspective side view) and 40B (bottom view) illustrate different views of another embodiment of the apex joint 4005 that is functionally similar to the apex joint 305 shown in fig. 5A for constructing the pyramid structures of the main frame 3740 (e.g., the main frame pyramid structures 3750A and 3750c as shown in fig. 39B) rather than the intersecting main frame pyramid structures (e.g., 3750B as shown in fig. 39B). In certain embodiments, the apex joint 4005 and its connected base joint may be made of a metallic material and are structural units used to construct the airship.

In a particular embodiment, the assembled apex joint 4005 (e.g., corresponding to apex joint 4005a or 4005B shown in fig. 38 and 39B) may be configured with a slot for receiving a connector/rod. From the perspective shown in fig. 40A-40B, a slot 4011 for receiving a vertex connector (e.g., connector 3820 or 3821 shown in fig. 38) is shown. In particular embodiments, the slot 4011 can be configured to receive and substantially surround a tubular object. In a particular embodiment, a similar slot 4012 for receiving another vertex connector may be formed on an opposite end of the vertex joint 4005. The opening or end of the slot (not visible from the perspective of fig. 40A-40B) will be at 4012. In a particular embodiment, the slots 4011 and 4012 can be symmetric about an imaginary vertical plane that bisects the apex joint 4005 through the center between the slot 4011 and the slot 4012. In particular embodiments, each of the slots 4011 and 4012 can be substantially cylindrical. In certain embodiments that use pyramid structures to construct straight structures (such as the gangway pieces described below), the cylindrical slots for receiving the apex joints of the apex connectors may be aligned with one another to form straight lines (in other words, the axes of the cylindrical slots may coincide). On the other hand, in embodiments that use pyramid structures to construct a circular master frame, such as the embodiment shown in fig. 37B, the outer angle (i.e., the angle measured from the exterior of the joint body and not through the body) between the two cylindrical slots 4011 and 4012 (or their corresponding axes) may be less than 180 degrees. The specific angle depends on the geometry of the main frame. In a particular embodiment, the circular main frame may approximate a regular polygon (e.g., a 36-sided polygon). In this way, the angle between the two connectors created by the vertex joint 4005 may correspond to the vertex of a polygon or the interior angle of a corner. The angle may depend on the number of vertices/angles the polygon is designed to have. For example, the sum of the internal angles of the polygon may be determined based on the formula (n-2) × 180 degrees, where n is the number of vertices/angles of the polygon (the sum of the external angles of all vertices/angles of the polygon is 360 degrees). Thus, for example, each internal angle of a regular polygon may be determined based on the formula ((n-2) × 180)/n.

In a particular embodiment, the vertex joint 4005 can also include a slot 4013 for receiving a vertex-to-base connector (e.g., connector 3815 shown in fig. 38). In a particular embodiment, the apex joint 4005 may have four such apex-to-base slots 4013, 4014, 4015, and 4016 to form a pyramid structure. Since each side of the pyramid structure is triangular, the angle between each pair of vertices corresponding to the vertices of the sides of the triangle to the base's trough depends on the desired geometric characteristics of the pyramid. For example, if the sides of the pyramid structure were identical equilateral triangles, the angle between each pair of vertices to the base's trough would be substantially 60 degrees.

In particular embodiments, each trough (e.g., 4011, 4013, etc.) may have one or more apertures into which liquid binder may be injected. With the rod/connector inserted, liquid adhesive may be injected into one or more of the holes, and air bubbles and/or excess adhesive may be allowed to escape from one or more of the other holes. This mechanism for joining the fitting and the parts of the connector may be applied to any of the fittings described herein.

Fig. 41A and 41B illustrate different perspective views of alternative embodiments of base joints 4100 used to construct the pyramid structure (e.g., as shown in fig. 38) of the main frame 3740. In particular embodiments, base joint 4100 may be made of metal or any other similar material. In particular embodiments, base joint 4100 can include one or more grooves. For example, base joint 4100 may have eight slots 4101, 4102, 4103, 4104, 4105, 4106, 4107, and 4108 (not visible in fig. 41A, but visible in fig. 41B). In particular embodiments, each of slots 4101-4108 may be configured to receive and substantially enclose a tubular object, such as a connector. In particular embodiments, each of slots 4101-.

In a particular embodiment, the base joint 4100 can have a total of eight grooves: a central slot 4108 for receiving a connector (e.g., connector 3812 shown in fig. 38) that is common between the bases of two adjacent pyramids, a connection slot 4101 for connecting to some other structure (e.g., 6-way geodesic joint 4400), a first side slot 4102, a first diagonal slot 4103, a first apex slot 4104 for one pyramid, a second side slot 4107, a second diagonal slot 4106, and a second apex slot 4105 for the other pyramid. The side slots 4102 can be configured to receive a connector (e.g., 3811 in fig. 38) that connects the base joint 4100 with an adjacent base joint (e.g., 5200 in fig. 38) of a first angular cone (e.g., the pyramid 3750a), the diagonal slots 4103 can be configured to receive a connector (e.g., 3790 in fig. 38) that connects the base joint 4100 with a diagonal base joint 4600 of the first angular cone 3750a, and the apex slots 4104 can be configured to receive a connector (e.g., 3816 in fig. 38) that connects the base joint 4100 with an apex joint (e.g., 4005a in fig. 38) of the first angular cone 3750 a. Other slots 4105 and 4107 may be used to form corner structures of a second adjacent pyramid (e.g., pyramid structure on the right side of pyramid structure 3750 a). Similar to slots 4102 and 4104, the side slots 4107, diagonal slots 4106 and vertex slots 4105 of the base joint 4100 can be configured to receive connectors that connect the base joint 4100 with adjacent base, diagonal base and vertex joints, respectively, of a second pyramid structure.

In certain embodiments that use pyramid structures to construct straight structures (such as the ramp pieces described below), the cylindrical side troughs of the base joint (similar to troughs 4102 and 4107) may be aligned with each other to form straight lines (in other words, the axes of the cylindrical troughs may coincide). On the other hand, in embodiments where a pyramid structure is used to construct a circular main frame, such as the embodiment shown in fig. 37B, the interior angle between two cylindrical side slots (or their corresponding axes) (i.e., the angle at which the opening points toward the center of the main frame) may be less than 180 degrees. In a particular embodiment, the circular main frame may approximate a regular polygon (e.g., a 36-sided polygon). As such, the angle between the two connectors created by base joint 4100 may correspond to the vertex of a polygon or the interior angle of a corner. The angle may depend on the number of vertices/angles the polygon is designed to have. For example, the sum of the internal angles of the polygon may be determined based on the formula (n-2) × 180 degrees, where n is the number of vertices/angles of the polygon (the sum of the external angles of all vertices/angles of the polygon is 360 degrees). Thus, for example, each internal angle of a regular polygon may be determined based on the formula ((n-2) × 180)/n.

As described above, the base joint 4100 may include a central slot 4108 and two side slots 4102 and 4107. In particular embodiments, central slot 4108 can be substantially perpendicular to each of side slots 4102 and 4105. Also as described above, the base joint 4100 may form a corner joint of two adjacent pyramid structures, as shown in fig. 38. As such, the central slot 4108, side slots 4102, and apex slot 4104 can define and support a corner structure of one pyramid (e.g., pyramid structure 3750a), and the central slot 4108, side slots 4107, and apex slot 4105 can define and support a corner structure of another pyramid. For each pyramid, such as pyramid 3750a formed using slots 4108, 4102, and 4104, the angle between the apex slot 4104 and the central slot 4108 and the angle between the apex slot 4104 and the side slots 4102 depend on the desired geometric characteristics of the pyramid. For example, if each side of the pyramid structure is an equilateral triangle (the base of the pyramid is not referred to as a side), the angle between the vertex slot 4104 and the center slot 4108 and the angle between the vertex slot 4104 and the side slots 4102 are both substantially 60 degrees. In particular embodiments, the corresponding structures for the other half of the base joint 4100 can have the same configuration.

In particular embodiments, each trough may have one or more holes into which the liquid adhesive may be injected. With the rod/connector inserted, liquid adhesive may be injected into one or more of the holes, and air bubbles and/or excess adhesive may be allowed to escape from one or more of the other holes. This mechanism for joining the fitting and the parts of the connector may be applied to any of the fittings described herein.

Fig. 42 shows an alternative example of an apex joint 4275, similar in function to apex joint 375 in fig. 3B, for use in constructing a pyramid structure of a gangway, such as the structure shown in fig. 39B. The apex joint 4275 of the pyramid structure of the gangway piece is similar to the apex joint 4005 of the pyramid structure of the main frame. Four of the notches are apex-to-base slots (the openings of slots 4213, 4214 and 4215 are shown; the opening of the fourth slot is hidden from view but is located within slot 4216). Slots 4213 and 4214 are symmetrical to slots 4215 and 4216 about an imaginary plane passing through the center of joint 4275. The other two notches 4211 and 4212 are apex-to-apex slots. Although these apex-to-apex slots are similar to those of the apex joint 4005 of the main frame, they differ in that their axes are aligned. In certain embodiments, the interiors of slots 4211 and 4212 may not be connected, meaning that two separate connectors would need to be inserted into both slots. In other embodiments, the interior of slots 411 and 4212 may form a continuous channel through which a single connector may be inserted. Other features of the apex joint 4275 are similar to those of the apex joint 305 or 4005 of the main frame and therefore will not be repeated for the sake of brevity.

Fig. 43A-43B illustrate an example of a gangway-to-geodesic base joint 4300 of a pyramid structure of gangways (e.g., the pyramid 3943 in fig. 39B). The pyramid structure 3943 of the gangway may be configured adjacent to the geodesic structure, as shown in fig. 39B. Thus, in the embodiment of the gangway to geodesic base joint 4300, the gangway to geodesic base joint 4300 contains nine slots to support two adjoining gangway pyramids and adjoining geodesic structures. The base-to- base slots 4301, 4302, and 4303 are configured to support connectors that form the bases of two adjoining ramp pyramid, which will be referred to as ramp pyramids a and B (pyramid structures 3943 and 3944 in fig. 39B). In particular, the slot 4302 is used to form a side portion that is common between the bases of adjacent ramp pyramid a and B, and the slots 4301 and 4303 are used to form the sides of two adjacent ramp pyramids that are located on the same side of the ramp, respectively. The base-to-apex slots 4308 and 4309 are used to connect the gangway-to-geodesic base connector 4300 to the apex of two adjacent gangway pyramids, respectively. For example, slot 4308 may be used to connect to the apex of pyramid a and slot 4309 may be used to connect to the apex of pyramid B. The gangway to geodesic base connector 4300 may also have base to geodesic slots 4304 and 4305 for connecting the gangway to geodesic base connector 4300 to an adjoining geodesic structure (e.g., slot 4304 may connect to the 6-way geodesic connector 4400a in fig. 39B). The gangway to geodesic base joint 4300 may also have slots 4306 and 4307 for diagonally connecting across the gangway to a 6-way geodesic joint (e.g., 4400B), which is also configured to connect the other side of the base of the gangway pyramid structure to the geodesic structure. This 6-way geodesic joint (e.g., 4400b) is part of the base of each ramp pyramid structure (e.g., 3943). As an example, the gangway to geodesic base connector 4300 is connected to the 6-way geodesic connector 4400b via its slot 4306. The slots 4301 and 4307 are all substantially in the same plane. On the other hand, the base to apex slots 4308 and 4309 used to form the sides of the pyramid are configured to form an angle with the plane.

Fig. 44 shows an alternative embodiment of a 6-way geodesic joint 4400 that functions similarly to the joint 330 shown in fig. 3C having six connector notches. In certain embodiments, the 6-way ground wire joint 4400 is used to form a ground wire structure, as shown in fig. 39A and 39B. As shown in fig. 39A, in one embodiment, the geodesic structure may include rows of triangles with alternating orientations, where the 6-way geodesic junction 4400 anchors intersections between three triangles from one row and three adjacent triangles from an adjacent row. Each 6-way ground wire joint 4400 can have six connector slots 4401, 4402, 4403, 4404, 4405, and 4406. In certain embodiments, two connector slots 4401 and 4402 on opposite sides of the tab 4400 can form a channel through the tab 4400 to allow a single longitudinal connector 3990 to pass through. In other embodiments, the interior of the connector grooves 4401 and 4402 may be unconnected, thus requiring separate longitudinal connectors 3990 to be inserted into the grooves 4401 and 4402, respectively. In one embodiment, 6-way ground trace structure 4400 may include an "X" pattern formed by grooves 4403, 4404, 4405, and 4406, which are placed below (or above, depending on their orientation when viewed) grooves 4401 and 4402. The ground trace structure 3999 may be formed by connecting each slot of a 6-way ground trace junction 4400 with a slot of another 6-way ground trace junction 4400, as shown in fig. 39A. The connector slots 4401 or 4402 of a series of 6-way ground wire tabs 4400 can be connected to form a longitudinal row (e.g., a row formed by a series of longitudinal connectors 3990).

In a particular embodiment, in addition to forming the geodesic structure 3999, the 6-way geodesic joint 4400 may be used to form a portion of the base of the gangway pyramid structure and connect the gangway pyramid structure to the geodesic structure. For example, fig. 39B shows a 6-way geodesic ramp base joint 4400B for forming a portion of the base of the ramp pyramid structure 3943. In these embodiments, the connector slots 4401 and 4402 can connect to the base fittings (e.g., 4500 and 4700) on one side of the gangway pyramid structure. The connector slots 4403 and 4404 may connect to the ramp base joints (e.g., 4300 and 4600) on opposite sides of the ramp pyramid structure. The connector grooves 4405 and 4406 may be connected to two 6-way ground wire joints 4400 or to one 6-way ground wire joint 4400 and a main frame-to-ground wire joint 5000. Additional details of embodiments including a ground wire structure including only the 6-way ground wire connections 4400 can be found in fig. 39A.

Fig. 45A-45B show different perspective views of an example of a gangway-to-main frame base joint 4500 connecting two main frame pyramid structures at their bases to the gangway pyramid structures (the gangway-to-main frame base joint 4500 forms the corners of three pyramid structures). For example, referring to fig. 39B, a gangway-to-main frame base joint 4500 may connect main frame pyramid structures 3750B and 3750c to gangway pyramid structure 3943. The gangway to main frame base joint 4500 can include seven slots 4501, 4502, 4503, 4504, 4505, 4506, and 4507. The channel 4501 may be configured to connect to the 6-way geodesic base joint 4400 b. Slot 4502 may be connected to main frame-gangway-base-geodesic joint 4600. The slot 4503 may be connected to the ramp apex joint 4275 of the pyramid structure 3943. Slots 4504 and 4505 may be connected to main frame apex joints 4900 and 4005b of two adjacent main frame pyramid structures 3750b and 3750c, respectively. The slot 4506 may connect to the main frame to geodetic junction 5000. And slot 4507 may be connected to main frame base joint 5100.

Fig. 46A to 46B show an example of a main frame-gangway-base-geodesic joint 4600. In a particular embodiment, the main frame-gangway-base-geodesic joint 4600 may include eleven connector slots for connecting to multiple other joints in the gangway, the main frame, and the geodesic structure. The grooves 4601, 4606, 4602, 4607 and 4603 can be used to form the bases of two adjoining main frame pyramid structures, such as pyramid structures 3750a and 3750B shown in fig. 39B. Specifically, the grooves 4601 and 4602 may be used to form adjoining sides of the base of the pyramid structure 4750a (e.g., connected to tabs 4800 and 5200, respectively), and the groove 4606 may be used to form a diagonal connector of the base (e.g., connected to tab 4100, not shown in fig. 39B). Thus, the slots 4606 may be angled at 45 degrees relative to the slots 4601 and 4602. Similarly, the grooves 4603 and 4602 may be used to form the adjoining sides of the base of the pyramid structure 4750b (e.g., connected to the joints 4500 and 5200, respectively), and the groove 4607 may be used to form the diagonal connector for the base (e.g., connected to the joint 5100). Thus, the slots 4607 may be angled at 45 degrees relative to the slots 4602 and 4603. The slots 4603, 4605 and 4610 may be used to form one corner of an adjoining ramp pyramid structure 3943. The slots 4603 and 4610 may be used to form the adjoining sides of the base of the gangway pyramid structure 3943 (e.g., connected to the joints 4500 and 4300, respectively). The groove 4605 can be used to connect to the 6-way geodesic junction 4400b on the other side of the gangway pyramid structure 3943. The groove 4604 can be used to connect to another 6-way ground wire tab 4400a of an adjoining ground wire structure. The remaining three slots 4611, 4608 and 4609 connect to the apex junctions of adjacent pyramid structures. In particular, the connector slot 4611 connects to the apex joint 4275 of the adjoining gangway pyramid structure 3943; connector slot 4608 connects to apex connector 4005a of pyramid structure 3750 a; and connector slot 4609 is connected to apex connector 4900 of pyramid structure 3750B.

Fig. 47A-47B show different perspective views of an example of a gangway base joint 4700 of a pyramid structure of a gangway. In some embodiments, the pyramid structure of a gangway (e.g., pyramid structure 3944 in fig. 39B) may include a gangway to geodesic base joint 4300 on one side of the gangway base and staggered gangway base joints 4700 and 6-way geodesic gangway base joints 4400B on the other side of the gangway base. The intersecting gangway pyramid structure 3943 may be different from other gangway pyramid structures (e.g., 3944) in that its base is constructed using gangway to geodesic base joint 4300, gangway base joint 4700, and joints 4600 and 4500. In a particular embodiment, the ramp base joints 4700 may form adjacent corners of two adjacent ramp pyramid structures, such as pyramid structures 3944 and 3943. The gangway base joint 4700 may include three gangway base-to- base slots 4701, 4702, and 4703. The slots 4701 and 4703 may form the corners of the base of one ladder pyramid structure 3944 and the slots 4702 and 4703 may form the corners of the base of another ladder pyramid structure 3943. The slots 4701 and 4702 may connect to two adjacent 6-way geodesic base connections (e.g., 4400b), while the slot 4703 may connect to the gangway to geodesic base connection 4300 on the other side of the gangway. The base-to- apex slots 4704 and 4705 connect to the apex joints of the adjoining ramp pyramid structures 3944 and 3943. For example, the ladder base joint 4700 in fig. 39B may be connected to the apex joint of a ladder pyramid structure 3944 and the apex joint of an adjacent ladder pyramid structure 3943.

Fig. 48A and 48B show different perspective views of an example of a main frame to geodesic base joint 4800. Joint 4800 is configured to connect two main frame pyramid structures to the geodesic structure at the corners of each of their respective bases via longitudinal connectors. In fig. 39B, the base joint 4800 is used to form a corner of the main frame pyramid structure 3750a and an adjacent main frame pyramid structure (not shown) above it. The base sub 4800 can have six connector slots. The slots 4801 and 4802 may be configured to connect to adjacent main frame base joints (e.g., the base joint 4600 of the main frame pyramid structure 3750a in fig. 38B, although it is understood that the connector slots 4801 and 4802 of the main frame base joint 4800 may connect to main frame base joints of various types and configurations). The central connector slot 4805 can be connected to another base joint (e.g., 4100 shown in fig. 38) on the other side of the main frame, which is shared by the same two pyramid structures. The apex connector slots 4803 and 4804 can be configured to connect to the apexes of two main frame pyramid structures (e.g., the slot 4804 connects to the apex joint 4005a of the main frame pyramid structure 3750 a). Finally, the connector slot 4806 can be configured to connect to a 6-way ground wire joint 4400a of an adjacent ground wire structure via a longitudinal connector.

Fig. 49A and 49B show different perspective views of an example of the apex joint 4900 of the gangway to the main frame. In a particular embodiment, the splice 4900 includes eight connector slots 4901, 4902, 4903, 4904, 4905, 4906, 4907, and 4908. Apex-to-base connector slots 4901-. In a particular embodiment, the intersecting main frame pyramid structure 3750b may be adjacent to two main frame pyramid structures (e.g., 3750a and 3750c) and two intersecting ramp pyramid structures (e.g., 3943 and another intersecting ramp pyramid structure, not shown, on the other side of the intersecting main frame pyramid structure 3750 b). To connect to the vertices of those pyramid structures, the vertex joint 4900 may also include four vertex-to- vertex connector slots 4905 and 4908 that connect to the vertex joint 4005b of the main frame pyramid structure 3750c, the vertex joint of a fourth pyramid structure, not shown, the vertex joint 4275 of the gangway pyramid structure 3943, and the vertex joint 4005a of the main frame pyramid structure 3750a, respectively.

Fig. 50 shows an example of a main frame to geodesic wire joint 5000. The joint 5000 can include ten connector slots 5001, 5002, 5003, 5004, 5005, 5006, 5007, 5008, 5009, and 5010 to connect to a plurality of other joints. The grooves 5001-5010 may be used to form adjacent corners of two main frame pyramid structures (e.g., pyramid structure 3750c and the partially shown pyramid structure below it) and connect to the gangway piece (e.g., 4400b) and the adjoining geodesic structure. For example, as shown in fig. 39B, slot 5004 of joint 5000 can connect to joint 4500 to form one side of main frame pyramid structure 3750 c. Slot 5008 can be connected to joint 5300 on the other side of the master frame to form an adjacent side of master frame pyramid structure 3750 c. The slot 5006 may be connected via diagonal connectors to a joint 5100 located at the opposite corner of the main frame pyramid structure 3750 c. The slot 3007 may be connected to the apex joint 4005b of the main frame pyramid structure 3750 c. Similarly, grooves 5008, 5010, 5009, and 5005 can be used to form adjacent corners of adjacent main frame pyramid structures (partially shown). Grooves 5008 and 5010 can be used to form adjacent sides of the corner, groove 5009 can be used to form a diagonal through the base of the main frame pyramid structure, and groove 5005 can be used to connect to the apex joint of the main frame pyramid structure. Three other slots 5003, 5002, and 5001 may be connected to an adjoining geodetic structure via 6-way geodetic junction 4400. The slot 5002 can be connected to one 6-way geodesic joint via a longitudinal connector, and the slots 5003 and 5001 can be connected to 6-way geodesic joints in adjacent rows (e.g., slot 5003 can be connected to the 6-way geodesic joint 4400b in the side of the upper row that forms the gangway).

Fig. 51A and 51B show different perspective views of an example of a main frame base joint 5100. In a particular embodiment, the main frame base joint 5100 includes nine connector slots 5101, 5102, 5103, 5104, 5105, 5106, 5107, 5108, and 5109. The joint 5100 may be used to form adjoining corners of the gangway pyramid structure (not shown) on the intersecting main frame pyramid structure 3750b, main frame pyramid structure 3750c, and opposing side gangway pyramid structure 3943. Using fig. 39B as an example, the troughs 5101, 5104, 5102, and 5103 of the junction 5100 may be used to form the corners of the intersecting main frame pyramid structure 3750B. In particular, the connector slot 5101 can connect to a channel to main frame base joint 4500; the slot 5102 may be connected to the main frame-gangway-base-geodesic joint 4600 via a diagonal connector; trough 5104 may be connected to a main frame base joint 5200 and trough 5103 may be connected to a joint 4900. In a similar manner, the troughs 5101, 5106, 5105, and 5107 of the junction 5100 may be used to form adjoining corners of the main frame pyramid structure 3750 c. In particular, the connector slot 5101 can connect to a channel to main frame base joint 4500; channel 5107 may be connected to main frame vertex joint 4005B; channel 5105 can connect to base joint 5300; and the trough 5106 may be connected to the main frame to ground wire connection 5000 via a diagonal connector. Additionally, the trough 5108 can be used to form one side of an adjacent gangway pyramid structure (not shown), and the trough 5109 can be used to connect to the apex joint of the gangway pyramid structure.

Fig. 52A and 52B show different perspective views of an example of a main frame base joint 5200. In a particular embodiment, the main frame base joint 5200 includes nine connector slots 5201, 5202, 5203, 5204, 5205, 5206, 5207, 5208 and 5209. The joint 5200 may be used to form adjoining corners of intersecting main frame pyramid structure 3750b, main frame pyramid structure 3750a, a gangway pyramid structure (not shown) on the opposing side gangway pyramid structure 3943, and adjoining geodesic structures (not shown). Using fig. 39B as an example, the slots 5201, 5208 and 5209 of the joint 5200 can be used to form corners of intersecting main frame pyramid structures 3750B. In particular, connector slot 5201 may connect to main frame-ramp-base-geodesic joint 4600; slot 5209 may be attached to a main frame vertex joint 4900; and the slot 5208 can be connected to a base joint 5100. Similarly, slots 5201, 5202 and 5203 can be used to form corners of the main frame pyramid structure 3750 a. In particular, connector slot 5201 may connect to main frame-ramp-base-geodesic joint 4600; the slot 5202 may be connected to a main frame vertex joint 4005 a; and slot 5208 can be connected to base joint 4100 (not shown in fig. 39B, but shown in fig. 38). The slots 5205, 5206 and 5207 can be used to form corners of a gangway pyramid structure, which is not shown in fig. 39B, but would be located on the opposite side of the intersecting main frame pyramid structure 3750B relative to the gangway pyramid structure 3943. In particular, connector slot 5205 may be connected to the base joint of the pyramid structure to form one side of the gangway; the slot 5206 can be connected to the apex joint of the pyramid structure and the slot 5207 can be connected to a 6-way geodesic joint on the other side of the gangway, similar to joint 4400 b. Slot 5204 may connect to a 6-way ground trace junction 4400 of an adjacent ground trace structure (not shown).

Fig. 53A and 53B show different perspective views of an example of a main frame base joint 5300. In a particular embodiment, main frame base joint 5300 includes eight connector slots 5301, 5302, 5303, 5304, 5305, 5306, 5307, and 5308. Joint 5300 may be used to form a corner of the main frame pyramid structure 3750c and another adjoining main frame pyramid structure partially shown in fig. 39B. Using fig. 39B as an example, slots 5303, 5304, and 5306 of joint 5300 may be used to form corners of intersecting main frame pyramid structure 3750 c. In particular, the connector slot 5303 can be connected to the fitting 5100; slot 5304 may be connected to main frame vertex joint 4005 b; and the groove 5306 can be connected to the base joint 5000. Similarly, slots 5307, 5305, and 5306 may be used to form corners of adjoining, partially illustrated main frame pyramid structures. In particular, grooves 5306 and 5307 may be used to form the corners of the base of the pyramid structure, and groove 5305 may be used to connect to the vertices of the pyramid structure. Additionally, joint 5300 can be used to connect to an adjacent geodetic structure (not shown in fig. 39B). In particular, the slots 5301 can be connected to the 6-way ground contacts 4400 on the same row using longitudinal connectors; the groove 5308 can connect to a 6-way ground lead connection 4400 on another row of ground lead structures; and the groove 5302 can connect to a 6-way geodesic joint 4400 that is part of the base of the ramp piece pyramid structure.

The particular embodiments described herein, referred to as "roller coaster pieces," provide a safer, faster assembly structure and method for manufacturing an airship. Traditionally, airships remain stationary while being built, which means that builders must climb to great heights to build the airships. Embodiments of the roller coaster structure allow the airship (or partially completed portion thereof) to rotate during construction so that the builder can remain on the ground, thereby improving safety and speed. In a particular embodiment, each main frame of the airship may be manufactured on the ground by rotating the main frame to bring the portion on which it is working to a height suitable for a builder on the ground. Longitudinal support between the main frames may then be added to connect adjacent main frames.

Fig. 54 shows an example of a main frame assembled on a roller coaster jig, in which a main frame 5400 is provided on top of a jig 5410. It should be understood that the partially completed main frame may also be disposed on the jig 5410 at the time of its construction. In certain embodiments, the roller coaster may also include a tower 5420 to prevent the main frame 5400 from falling sideways off the clamp 5410.

Fig. 55A to 55B show an embodiment of a roller coaster clamp. In the embodiment shown in fig. 55A, the clamp 5510 may have a pair of rails 5511 extending parallel to each other. The distance between the tracks 5511 may depend on the width of the main frame that the roller coaster is designed to support. For example, the distance between the tracks 5511 may be configured to substantially match the width of the main frame. The track 5511 can form an arc, which can conform to the curvature of the main frame. The length of the track 5511 (or arc) may be any suitable length to provide sufficient support to the main frame. In the embodiment shown in fig. 55A, the track 5511 may be fixed to a stationary support structure 5512 (e.g., having a fixed height). In the embodiment shown in fig. 55B, the track 5521 may be fixed to an adjustable support structure 5522 (e.g., individually adjustable with respect to height), which may be used to adjust the height and/or curvature of the track 5521 of the roller coaster.

Fig. 56 illustrates a close-up view of one of the adjustable support structures 5522. Each rail 5521 can be attached to an attachment block 5631. The attachment block 5631 may be secured to an adjustable platform 5632, which in turn may be secured to the body of the clamp 5633.

In certain embodiments, the outer surface of the main frame may have detachable wheels configured to interface the main frame with the track of the roller coaster and allow the main frame to rotate along its axis. Fig. 57A-57B illustrate an embodiment of a detachable wheel 5700. A removable wheel 5700 may be secured at or near each base joint of the main frame. In certain embodiments, the wheels 5710 may have a concave surface to improve their fit on top of the convex track. In particular embodiments, the wheels may have a recessed surface to fit on a recessed track (the recess of the track may form a channel into which the wheels may be placed). In certain embodiments, the housing 5720 for the wheel 5710 may be manufactured using carbon fiber twill cloth, similar to those used for the apex and base joints described above. For example, housing 5720 may be manufactured using a 3D printed mold. In certain embodiments, screws can be used to secure the housing 5720 to the main frame and the wheel 5710. In another embodiment, two wheels may be attached to opposite ends of the elongated housing. The top side of the housing may have an adjustable clamp that can be clamped to a connector of the main frame, e.g. any connector that forms the base of the pyramid structure. Once the airship is complete, the detachable wheels may be detached from the main frame of the airship.

In particular embodiments, the main frame may be rotated manually on the roller coaster rig (e.g., by sliding it over a surface of the roller coaster rig or by manually rocking a lever to rotate the main frame on the roller coaster rig). In other embodiments, a power drive unit may be used to facilitate rotation of the main frame on the roller coaster member. In particular embodiments, the drive unit may be pneumatic, electric, or powered by any other form of energy. In particular embodiments, a plurality of roller coaster members may be arranged side by side, each roller coaster member having a corresponding main frame. The roller coaster members may be engaged simultaneously to rotate all of the corresponding main frames. In this way, a large section of the airship body, including multiple sections of the main frame, may be rotated for assembly. In certain embodiments, a drive unit attached to each of the plurality of roller coaster members may facilitate rotation. In certain embodiments, the drive units may be synchronized mechanically or electronically (e.g., by a central computer) such that each segment of the main frame is simultaneously rotated by an appropriate angle of rotation.

The above described apparatus can be used to efficiently and cost effectively build airships. In certain embodiments, each of the above-described joints used in the construction of the rigid airship frame may be manufactured using a mold. In particular embodiments, any of the molds described herein can be manufactured as follows. Each part of the mold (e.g., male mold, female mold, or center part) can be quickly and cost-effectively produced using a 3D printer. For example, a digital 3D model defining a mold part may be sent to a 3D printer for printing. The 3D printer may "print" the mold parts layer by layer based on their digital model. Any sufficiently strong material may be used, including but not limited to: nylon, ABS plastic, metal, resin, etc. In a particular embodiment, the mold part may be a solid piece with 3D printed material. In other embodiments, the mold parts may be designed with a central cavity body in the middle with an external opening to the cavity built in. Once the shells of the mould parts have been 3D printed, cement or other suitable type of material can be injected into the cavity through the openings. Advantages of this process include, for example, reinforcing the mold parts to a strength that exceeds that provided by the 3D printed material alone, reducing 3D printing time (because less quality is printed), and reducing the costs associated with 3D printing. Once the cement hardens, the mold part will be ready for use.

In certain embodiments, the mold parts may be used to press against joint material to create a joint for a rigid airship. In particular embodiments, carbon fiber twill cloth may be used because of its desirable properties of being strong, lightweight, rigid, and initially flexible. The carbon fiber twill may be treated with a hardener, such as an epoxy resin. Thereafter, multiple layers of twill may be placed between the mold parts. In certain embodiments, to assist in the subsequent separation of the pressed carbon fiber twill from the mold parts, a layer of plastic sheet material may be placed between the twill and each mold part. The mold sections may then be pressed together so that the corresponding portions designed to fit together are aligned with each other. An appropriate amount of force may be applied to the mold to maintain its pressed configuration and shape the carbon fiber twill until it hardens. The force may be applied, for example, by using a clamp, a weight, or any other suitable means. Once the carbon fiber twill hardens, the mold parts may be separated from each other to allow removal of the carbon fiber twill. In certain embodiments, the hardened carbon fiber twill, which in turn serves as a joint component, may then be trimmed to remove undesired or unwanted portions.

The joint components can then be used to construct the frame of a rigid airship. In certain embodiments, the components of the joint may be secured to one another to form a desired joint. For example, the male and female halves of the apex joint of the main frame may be assembled as shown in FIG. 5A. In certain embodiments, the joint components may be secured by using bolts, adhesive, or any other suitable adhesive. Any such fastening means may be applied to surfaces where the tab portions abut one another. For example, fig. 5A shows that other portions of the male and female halves are substantially in contact, except for the portion where the slots are formed. For example, a liquid adhesive may be applied to such surfaces to bond the components together to form the joint. In certain embodiments, the tabs may first be permanently formed in this manner, and then the connectors may be inserted into the slots. In other embodiments, the connectors may be positioned before the joint is permanently assembled. For example, the connector may be positioned with only the male half of the fitting, and then the female half may be assembled in place. In fact, the male and female halves can be used to clasp the connector when the connector is located in the designated slot.

In certain embodiments, the connector may be secured to the fitting using a liquid adhesive. For example, adhesive may be applied to the inner surface of the slot and/or the end of the connector to be inserted into the slot. In certain embodiments, the bonding surfaces of the slot and the connector may be pre-treated with an adhesive prior to placing the connector into the slot. In certain embodiments, the connector may be inserted into the joint first, and then the adhesive may be injected into the space between the abutting surfaces. In this case, a hole may be drilled in each slot prior to insertion of the connector. For example, for a given slot of a fitting, a corresponding portion in the male half may have a hole, and a corresponding portion in the female half may similarly have a hole. After the connector has been inserted into the slot, a liquid adhesive may be injected through one of the holes into the slot to bond the inner surface of the slot with the insertion end of the connector. During the injection process, air bubbles and excess adhesive may flow out of the other hole. When the adhesive dries, a snap ring, a strap, a rubber band, or any other type of restraining device may be used to hold the connector and slot in place. In particular embodiments, to confine the injected liquid adhesive to a limited area within the groove, and/or to ensure that there is a sufficient amount of adhesive between the inserted connector and the interior of the groove, the area within the groove surrounding the hole may be divided to prevent the injected adhesive from oozing beyond that area. For example, two O-rings or similar devices may be attached to the end of the connector or to the inner surface of the groove. The two O-rings may be spaced apart so that upon insertion of the connector, the O-rings will define an area around the hole in the groove through which the adhesive is injected. The O-ring acts as a barrier preventing the injected adhesive from extending beyond the defined area.

In certain embodiments, the main frame may be assembled using the above-described joints and connectors (e.g., carbon fiber or metal embodiments). In particular embodiments, the main frame may be built on top of a roller coaster clamp. For example, after the pyramid structure of the main frame has been constructed, detachable wheels may be attached to the corners of the pyramid base. The pyramid structure can then be placed onto a roller coaster jig with the wheels aligned with the rails of the jig. Additional pyramid structures can be similarly constructed on the jig and connected to each other. The engineer may rotate the partially assembled main frame on the roller coaster jig as required so that the engineer on the ground may still access the section to be machined. This not only provides a much safer working environment (since the engineer does not have to climb to a high height), but also improves efficiency.

In a particular embodiment, the assembled main frames may be placed parallel to each other such that a boat section may be built therebetween. In a particular embodiment, both main frames may be placed on a roller coaster jig and rotated such that the corresponding pyramid structures of the two main frames are aligned. In a particular embodiment, extension joints (such as those described with reference to fig. 20-36) may be attached to the joints of the main frame. Using those extension joints, gangway pieces (e.g., four evenly spaced gangway pieces such as those shown in fig. 1) may be constructed to connect the main frames. If metal joints are used instead (e.g. fig. 37 to 53), the grooves for connecting the main frame to the gangway and geodesic structures are integral with the joints, without the need to extend the joints. In particular embodiments, the remainder between each pair of main frames may be constructed using geodesic structures as described herein. In a particular embodiment, the geodesic structure may comprise a longitudinal connector connecting each base joint of one main frame to a corresponding base joint of another main frame. To add additional structural support, the geodesic structure may also include intersecting diagonals, thereby forming the "X" pattern or 6-way geodesic pattern described above. In this way, a boat body section of an airship may be constructed. Additional boat segments may be similarly constructed and connected to each other to form a frame of the rigid airship.