An additive manufacturing apparatus an extruder configured to receive material, a work surface extending so as to define a plane for receiving one or more layers of the material, an applicator assembly secured at a downstream portion of the additive manufacturing apparatus, a nozzle connected to the applicator assembly, the nozzle being configured to receive the material from the extruder and deposit the material on the work surface, and an actuator configured to displace the work surface in a movement direction, wherein the movement direction forms an acute angle with the plane.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
An additive manufacturing apparatus includes an extruder configured to receive a thermoplastic material and an applicator assembly downstream of the extruder, the applicator assembly including a nozzle for depositing the thermoplastic material as a plurality of layers. The additive manufacturing apparatus also includes a temperature sensor configured to detect a temperature of at least a portion of a deposited layer and a positioning assembly configured to change an angular position of the temperature sensor.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
A multi-axis machine includes a horizontally-displaceable carriage, a vertically- displaceable column, a spindle supported distally of the column, a motor configured to change a position of at least one of the carriage, the column, or the spindle; and an impact detection mechanism. The impact detection mechanism includes a first plate, a second plate secured distally of the first plate, and a sensor configured to detect a motion of the second plate with respect to the first plate.
G05B 19/402 - Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for positioning, e.g. centring a tool relative to a hole in the workpiece, additional detection means to correct position
B23Q 11/00 - Accessories fitted to machine tools for keeping tools or parts of the machine in good working condition or for cooling workSafety devices specially combined with or arranged in, or specially adapted for use in connection with, machine tools
G05B 19/401 - Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes
5.
METHODS AND SYSTEMS FOR INCREASING PRINT SPEED DURING ADDITIVE MANUFACTURING
An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.
An additive manufacturing method ay includes depositing thermoplastic material with an additive manufacturing apparatus to form a first section of a mold of a marine article. The first section includes an interior surface having a shape corresponding to a first portion of a hull of the marine article and a support portion including a support surface, the support portion being integrally formed with the interior surface. The method also includes depositing thermoplastic material to form a second section of a mold of a marine article, the second section including an interior surface having a shape corresponding to a second portion of a hull of the marine article. The method also includes joining the first section and the first section together to form at least a portion of the mold.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
A mold assembly for producing a part includes a first section, a second section movably coupled to the first section, and a cavity defined by the first section and the second section, the cavity being shaped to receive a part while the first section and the second section are movably coupled to each other. The mold assembly includes a joint formed by adjacent surfaces of the first section and the second section and a seal extending along the joint.
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
An additive manufacturing method includes providing material to an extruder (61) of an additive manufacturing apparatus, heating the material to form a flowable material, and depositing a first layer of the flowable material from a nozzle (51) of the additive manufacturing apparatus to form part of a hull portion (81) of a plug for a marine article. The method also includes depositing a second layer of the flowable material from the nozzle (51) of the additive manufacturing apparatus to form part of a deck portion (82) of the plug for the marine article.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
An additive manufacturing apparatus includes a first vertically- extending support leg (85), a second vertically-extending support leg (86), and a gantry (26) supported on the first and second support legs (85, 86). The additive manufacturing apparatus also includes a work table (27) movably supported beneath the gantry (26), a print head (43) supported on the gantry (26), and a trim head (90 supported on the gantry (26) with the print head (43).
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.
An additive manufacturing apparatus includes an extruder and a gear pump in fluid communication with extruder. The additive manufacturing apparatus also includes a nozzle in fluid communication with the gear pump. The extruder is connected to a guide member such that at least a portion of the extruder is configured to expand and move along the guide member according to a thermal expansion of the extruder.
74378-23 ABSTRACT An additive manufacturing method includes receiving a design model indicative of a part that may be fabricated using the additive manufacturing method, and generating expected-warping information based on the design model, the expected- warping information being indicative of an expected change in a shape of the part resulting from the additive manufacturing method. The method also includes modifying the design model based on the expected-warping information and fabricating the part using the modified design model. 28 Date Recue/Date Received 2020-09-18
A system for additive manufacturing (1) includes a nozzle (51) configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle (51) is operably coupled to: an extruder (60) having an outlet and including a screw (63) disposed within a barrel (64), and a pump (66) having an inlet and an outlet. The inlet is coupled to the extruder (60), and the outlet is in fluid communication with the nozzle (51). The system also includes a controller configured to adjust a speed of the pump (66) with respect to a speed of the screw (63) to apply a target pressure at the outlet of the extruder (60)
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.
B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
A method for thermal compensation during an additive manufacturing process. In some aspects, the method may include receiving, at a CNC machine, information relating to a material used in the additive manufacturing process, wherein the received information includes at least a Coefficient for Thermal Expansion (CTE) for the material. The method may further include modifying a distance of travel for a first pre-programmed tool path based on at least the Coefficient for Thermal Expansion (CTE).
An exemplary additive manufacturing method may include heating a thermoplastic material within an extruder. The extruder may include an extruder screw extending in a vertical direction. The method may further include receiving the thermoplastic material from the extruder with a gear pump. A bead of the thermoplastic material may be deposited on a vertical worktable. The method may further include compressing the bead of thermoplastic material on the vertical worktable.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
An exemplary additive manufacturing system may include an extruder (61) having an opening dimensioned to receive a material. The extruder also may have a barrel (42) and a screw (80) within the barrel. The screw may have a diameter ranging between about 20 mm and about 150 mm and the barrel extends along a longitudinal axis. The system may include one or more heaters (41) positioned along at least a portion of the barrel. As the material passes through the barrel, the one or more heaters may at least partially melt the material. The system may further include a gear pump (74) in fluid communication with the barrel for receiving the at least partially melted material. Additionally, the system may include a nozzle (51) in fluid communication with the gear pump for depositing the at least partially melted material. The system also may include a vertical worktable (37).
An additive manufacturing system (1) may include a nozzle (51) having an inlet for receiving a flowable material (53) and an outlet for depositing the flowable material. The system also may include an applicator head (43) surrounding at least a portion of the nozzle. Additionally, a roller (59) may be mounted on the applicator head and rotatable about an axle (73). A coolant circuit may extend through at least a portion of the applicator head and through a lumen of the axle.
Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder (61), the extruder having an opening (40) dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters (41) positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump (74) in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle (51) in fluid communication with the gear pump for depositing the at least partially melted material.
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
Additive manufacturing system, which may include a nozzle (51) having an inlet for receiving a flowable material (53) and an outlet for depositing the flowable material (53). An applicator head (43) may surround at least a portion of a proximal region of the nozzle (51). The applicator head (43) may include a housing (46), a cooling inlet for receiving a coolant into the housing (46), a cooling outlet configured to allow the coolant to exit the housing (46), and an air inlet. A roller (59) may be mounted on the applicator head (43) to one side of the outlet of the nozzle (51). The roller (59) may include an air outlet, wherein a flow path connects the air inlet and the air outlet so that air enters the air inlet and exits the air outlet. The roller (59) may also include a plurality of holes (70) located on an external surface of the roller (59).
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
25.
APPARATUS AND METHOD FOR PRINTING LONG COMPOSITE THERMOPLASTIC PARTS ON A DUAL GANTRY MACHINE DURING ADDITIVE MANUFACTURING
Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary apparatus for fabricating components via additive manufacturing may include a programmable CNC machine. The CNC machine may comprise a first worktable extending in a first plane and a second worktable extending in a second plane, wherein the second plane is oriented at an angle relative to the first plane. At least one conveyor belt may be operably coupled to the first worktable. A printing gantry may be displaceable along a first axis of the CNC machine. The CNC machine may also comprise an applicator having a nozzle configured to deposit material on the second worktable.
An additive manufacturing method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, the nozzle being configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes. In one embodiment, the method includes actuating an extruder to form a flowable material, delivering the flowable material to a pump, sensing a pressure of the flowable material, and adjusting at least one of a speed of the extruder and a speed of the pump based on at least one of the sensed pressure and a rate of translation of the nozzle along one or more of the first, second, and third axes.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
27.
METHODS OF SECURING AN INITIAL LAYER DURING ADDITIVE MANUFACTURING OF THERMOPLASTIC MATERIAL
In one embodiment, an additive manufacturing method including the steps of positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed; depositing a first plurality of layers of a flowable material on at least some of the plurality of pellets; and depositing a second plurality of layers of the flowable material on the first plurality of layers.
B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.