An additive manufacturing method includes receiving an electronic representation of a part with a control system, determining a plurality of layers for the electronic representation of the part, and separating one or more of the layers associated with the electronic representation of the part into a plurality of segments. The additive manufacturing method further includes adding a joint structure to two or more of the segments and generating instructions for controlling a machining apparatus based on the electronic representation of the part, the layers, the segments, and the joint structure.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
B22F 12/82 - Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
B32B 37/00 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
G05B 19/4097 - 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 using design data to control NC machines, e.g. CAD/CAM
G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
2.
METHODS AND SYSTEMS FOR PRODUCING BOAT MOLDS BY ADDITIVE MANUFACTURING
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]
B29C 33/38 - Moulds or coresDetails thereof or accessories therefor characterised by the material or the manufacturing process
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]
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
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]
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]
6.
SYSTEMS AND METHODS FOR PRINTING COMPONENTS USING ADDITIVE MANUFACTURING
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.
An additive manufacturing system may include an extruder. The extruder may include a barrel having a bore. Additionally, the extruder may include an extruder screw at least partially received within the bore of the barrel. The additive manufacturing system also may include a gear pump fluidly coupled to the bore of the barrel. The extruder screw may extend at least partially into the gear pump.
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 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.
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).
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).
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]
13.
METHODS AND APPARATUS FOR COMPENSATING FOR THERMAL EXPANSION DURING ADDITIVE MANUFACTURING
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.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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]
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 64/124 - 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
B29C 64/386 - Data acquisition or data processing for additive manufacturing
16.
METHOD OF FORMING THREE-DIMENSIONAL DECORATIVE ITEMS
Aspects of the present disclosure relate to methods for fabricating components, for example, 3D decorative items. In an embodiment, a method including positioning a spoil board on a worktable of a computer numeric control (CNC) machine; operating the CNC machine in a first mode to create an outline in the spoil board; positioning a first workpiece on the spoil board and over at least a portion of the outline; and operating the CNC machine in a second mode to cut into a portion of the first workpiece.
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.
An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold (62) having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.
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.
A CNC machine for additive manufacturing including a worktable (21) displaceable along a y-axis, a gantry (24) disposed along an x-axis, either fixed or displaceable along the y-axis, a carriage (27) on such gantry displaceable along the x-axis and including a thermoplastic material extrusion conduit, a tool carrier (31) mounted on such carriage displaceable along a z-axis, a dispersion conduit mounted on such tool carrier accommodating an applicator (70), means mounted on such applicator for extruding a molten bead of a thermoplastic material (71, 72), a flexible hose (60) interconnecting such molten material forming means and such applicator, a plurality of servomotors (41, 46, 66) for linearly or rotationally displacing such components along or about such axes and a computer for controlling such component displacements.
B29C 67/00 - Shaping techniques not covered by groups , or
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
B25J 9/02 - Programme-controlled manipulators characterised by movement of the arms, e.g. cartesian co-ordinate type
B25J 19/00 - Accessories fitted to manipulators, e.g. for monitoring, for viewingSafety devices combined with or specially adapted for use in connection with manipulators
An assembly mountable on a machine including a gantry displaceable along a y axis, a tool carrier mounted on such gantry displaceable along a z-axis, a tool holder mounted on such tool carrier displaceable about a z-axis, a tool support shaft provided with an axis disposed in an x-y plane journalled in such tool holder and displaceable about the axis thereof, a dispersion conduit mounted on such shaft, perpendicular to such shaft axis, means on such dispenser conduit for ejection a molten beam of thermoplastic material and a flexible hose with a first end supported on such carrier forming a rotary with such extension conduit, and a second end communicating with an inlet of such dispenser conduit.
B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
B29C 67/00 - Shaping techniques not covered by groups , or
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
patents
