Methods and associated systems and apparatus for determining a tool path (335) for use in additively manufacturing a structure. The methods includes identifying a propagation surface onto which material forming at least part of the structure is to be deposited, and determining a structure boundary associated with the propagation surface and defining at least part of the structure. The methods may also include determining one or more structure layers offset from the propagation surface and laterally bounded by the structure boundary; generating a tool path for each structure layer (335).
A method is disclosed for additively manufacturing of a joint (140, 240, 440, 650, 750, 850, 940, 1200) within a structure using a composite material. The method may include depositing a first path (160, 462, 652) of the composite material within a first layer at the joint. The first path may have a center portion at a center of the joint, and a first portion integral with the center portion and extending away from the center portion. The first portion may form at least part of a first branch having a first density. The center of the joint may have a second density. The first density may be greater than the second density.
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 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
A system (10) is disclosed for additively manufacturing an object (12). The system may include a support (14), and a print head (16) operatively connected to and moveable by the support. The print head may include an outlet (52) configured to discharge a material, a leading device (244), and a trailing device (234) pivotally connected to the leading device. The leading device may be configured to engage and move over the material after discharge. The trailing device may be configured to engage and move over the material at a location trailing the leading device.
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
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
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
A system (10) is disclosed for use in additively manufacturing an object (12). The system may have a reinforcement supply (44), a matrix supply (46), and a wetting module (52) configured to separately receive reinforcement from the reinforcement supply and matrix from the matrix supply and to discharge the reinforcement wetted with the matrix. The wetting module may include a body (152, 158) forming an enclosure and having an inlet end (154) configured to receive the reinforcement and an outlet end (156) configured to discharge the reinforcement wetted with the matrix. The wetting module may also include a plurality of nozzles (168) dividing the enclosure into at least a wetting chamber (170).
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A method is disclosed for us in additively manufacturing a three- dimensional carbon-bonded composite article. The method may include discharging from a print head a curable composition. The curable composition may include a) at least one aromatic, actinically curable component having an H/Catomic ratio of from 0.4 to 1.6, selected from the group consisting of (meth)acrylate oligomers, epoxy-functionalized compounds, oxetane-functionalized compounds and mixtures thereof; and b) at least one diluent comprising at least one actinically curable monomer. The curable composition may also include c) a reinforcement, and d) a photoinitiator. The method may further include irradiating the curable composition during the discharging to at least partially actinically cure the curable composition and form a preform of the three-dimensional carbon- bonded composite article. The method also includes pyrolyzing the preform to form the three-dimensional printed carbon-bonded composite article.
C04B 35/524 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from polymer precursors, e.g. glass-like carbon material
C04B 35/626 - Preparing or treating the powders individually or as batches
C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like
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
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
B28B 1/00 - Producing shaped articles from the material
A method is disclosed for additively manufacturing a composite structure (12). The method may include discharging a composite material (C+R) from a print head (16) and moving the print head during discharging to fabricate a preform (12) from the composite material. The method may also include densifying the preform with a densifying material, and heating the preform to pyrolize the at least one of the composite material and the densifying 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]
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
A system (10) is disclosed for additively manufacturing a composite structure (12). The system may include a support (14), and a print head (16) operatively connected to and moveable by the support. The print head may include a supply of continuous reinforcement (19), an outlet (54) configured to discharge the continuous reinforcement, and a tensioning module (48) disposed between the supply and outlet. The tensioning module may be configured to generate a signal indicative of at least one of a tension in the continuous reinforcement and a position of a tensioning module. The system may also include a processor (20) programmed to selectively cause the supply to dispense the continuous reinforcement based on the signal.
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 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
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
8.
METHOD FOR ADDITIVELY MANUFACTURING A COMPOSITE STRUCTURE
A method is disclosed for additively manufacturing a composite structure. The method includes receiving from a user a sketch of a cross-section of the composite structure and a desired height. The method includes automatically generating a virtual model of the composite structure having a plurality of layers (1202), each with a thickness related to the height. The method further includes receiving from the user at least one infill pattern (1204) for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a continuous fiber along segments of the at least one infill pattern.
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 64/386 - Data acquisition or data processing for additive manufacturing
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system includes a support and a print head operatively connected to and moveable by the support. The print head includes a housing (22), a supply module (44) operatively mounted to the housing and configured to hold a supply of continuous reinforcement, an impregnation module (48) operatively mounted to the housing and configured to wet the continuous reinforcement with a matrix, and a clamping module (46) operatively mounted to the housing downstream of the supply module relative to movement of a reinforcement through the print head. The clamping module is be configured to selectively clamp the continuous reinforcement. A controller in communication with the support and the print head is configured to coordinate operations of the support and the print head to fabricate a three-dimensional structure.
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 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A method is disclosed for use in additively manufacturing a composite structure (12) from reinforcements (R) wetted with a matrix (M). The method may include slicing a virtual model of the composite structure into multiple slices that are adjacent to each other along a length direction of the composite structure and determining points of the reinforcements passing through each of the multiple slices. The method may further include clocking the points differently around each of the multiple slices and generating at least one tool path including a sequenced subset of the points. The method may additionally include causing an additive manufacturing machine (10) to discharge the reinforcements along the at least one tool path.
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B29C 70/32 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
B29C 70/16 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length
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
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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
G06F 30/20 - Design optimisation, verification or simulation
B29C 53/56 - Winding and joining, e.g. winding spirally
12.
SYSTEM FOR ADDITIVELY MANUFACTURING COMPOSITE STRUCTURE
An additive manufacturing system (10) is disclosed for use in fabricating a structure (12). The additive manufacturing system may include a support (14), and a print head (16) configured to discharge a material (R+M) and being operatively connected to and moveable by the support in a normal travel direction (34) during material discharge. The print head may include a module (22) located at a trailing side of the discharging material relative to the normal travel direction and being configured to compact the material and expose the material to a cure energy at a tool center point (TCP).
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
13.
SYSTEM FOR ADDITIVELY MANUFACTURING COMPOSITE STRUCTURE
An additive manufacturing system (10) is disclosed for use in discharging a continuous reinforcement. The additive manufacturing system may include a support (14), and a compactor (32) operatively connected to and movable by the support. The compactor may be configured to apply a pressure to the continuous reinforcement during discharge. The additive manufacturing system may also include a feed roller (34) biased toward the compactor to sandwich the continuous reinforcement between the roller and the compactor, and a cutting mechanism (46) at least partially recessed within at least one of the feed roller and the compactor. The cutting mechanism may be configured to selectively move radially outward to engage the continuous reinforcement.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
14.
SYSTEM FOR ADDITIVELY MANUFACTURING COMPOSITE STRUCTURE
An additive manufacturing system (10) is disclosed for use in fabricating a structure (12). The additive manufacturing system may include a support (14), and an outlet (22) configured to discharge a material. The outlet may be operatively connected to and moveable by the support in a normal travel direction during material discharge. The outlet may include a guide (30), and a compactor (32) operatively connected to the guide at a trailing location relative to the normal travel direction. The compactor may be moveable in an axial direction of the guide. The outlet may also include at least one cure enhancer (18) mounted to move with the compactor relative to the guide. The at least one cure enhancer may be configured to expose the material to a cure energy.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
15.
SYSTEM FOR ADDITIVELY MANUFACTURING COMPOSITE STRUCTURE
A system (10) for additively manufacturing a composite structure (12) is disclosed. The system may include a support (14), and a print head (16) operatively connected to and moveable by the support. The print head may be configured to discharge a continuous reinforcement that is at least partially coated in a liquid matrix. The system may also include a cure enhancer (18) connected to the print head and configured to expose the discharge to cure energy to cause the liquid matrix to at least partially polymerize, and a controller (22) in communication with the heater and the cure enhancer. The controller may be configured to selectively activate the heater and the cure enhancer.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
A system (10) is disclosed for additively manufacturing a composite structure (12). The system may include a print head (16) configured to discharge a continuous reinforcement (R) that is at least partially coated in a matrix (M), and a compactor (24) configured to compact the continuous reinforcement and the matrix. The system may also include a cure enhancer (20) configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor.
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 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
An additive manufacturing system includes a support, and a print head connected to and moveable by the support. The print head may have an outlet configured to discharge a continuous reinforcement at least partially coated in a matrix. The system may also include at least one doser located inside the print head and configured to at least partially coat the continuous reinforcement with the matrix, a sensor located downstream of the at least one doser and configured to generate a signal indicative of an amount of matrix coating the continuous reinforcement, and a controller. The controller may be configured to direct a feedforward command to the at least one doser to cause the at least one doser to advance matrix toward the continuous reinforcement during passage of the continuous reinforcement through the print head, and to selectively adjust the feedforward command based on the signal.
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 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
A system (10) is disclosed for additively manufacturing a composite structure (12). The system may include a support (14), and a print head (16) connected to and moveable by the support. The print head may have a first tool center point (TCP) associated with discharge of a first material, and a second tool center point (TCP) associated with discharge of a second material that is a type different than the first material.
B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
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 (10) is disclosed for additive manufacturing of a composite structure (12). The system may include a support (14), and a print head (16) connected to and moveable by the support. The print head may include an outlet (24) configured to discharge a continuous reinforcement at least partially coated in a matrix. The outlet may be moveable relative to the support. The print head may also include at least one actuator (30) configured to cause movement of the outlet relative to the support.
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
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
A method is disclosed for operating an additive manufacturing system (10). The method may include wetting a reinforcement with a thermoset matrix inside of a print head (16), discharging the wetted reinforcement from the print head, and moving the print head in multiple directions during discharging. The method may also include exposing the thermoset matrix wetting the reinforcement to a cure energy to initiate a chemical reaction, and directing a medium onto the wetted reinforcement to regulate a rate of the chemical reaction.
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
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
21.
FIBER MANAGEMENT ARRANGEMENT AND METHOD FOR ADDITIVE MANUFACTURING SYSTEM
A method is disclosed for severing a continuous reinforcement (R) from a print head (16) at conclusion of an event during fabrication of a composite structure (12). The method may include moving the print head a distance away from the composite structure that provides clearance for a cutting mechanism (30) between an outlet (18) of the print head and the composite structure, and responsively causing the cutting mechanism to make a first cut of the continuous reinforcement at a boundary of the composite structure. The method may also include moving the print head to a waste discard location (36), and responsively causing the cutting mechanism to make a second cut of the continuous reinforcement at a desired distance offset from the outlet of the print head..
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
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 70/16 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length
patents
