WO2018140181A1 - Additive manufacturing system implementing anchor curing - Google Patents

Additive manufacturing system implementing anchor curing Download PDF

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Publication number
WO2018140181A1
WO2018140181A1 PCT/US2017/068019 US2017068019W WO2018140181A1 WO 2018140181 A1 WO2018140181 A1 WO 2018140181A1 US 2017068019 W US2017068019 W US 2017068019W WO 2018140181 A1 WO2018140181 A1 WO 2018140181A1
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WO
WIPO (PCT)
Prior art keywords
matrix
cure
print head
coated reinforcement
offboard
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2017/068019
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English (en)
French (fr)
Inventor
Kenneth Tyler
Ryan C. STOCKETT
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CC3D LLC
Original Assignee
CC3D LLC
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Filing date
Publication date
Application filed by CC3D LLC filed Critical CC3D LLC
Publication of WO2018140181A1 publication Critical patent/WO2018140181A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/12—Formation of a green body by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B29C48/08—Flat, e.g. panels flexible, e.g. films
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C64/135—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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/382—Automated fiber placement [AFP]
    • B29C70/384—Fiber placement heads, e.g. component parts, details or accessories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/683—Pretreatment of the preformed part, e.g. insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1035—Liquid phase sintering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1103—Making porous workpieces or articles with particular physical characteristics
    • B22F3/1118—Making porous workpieces or articles with particular physical characteristics comprising internal reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C2033/0005—Moulds or cores; Details thereof or accessories therefor with transparent parts, e.g. permitting visual inspection of the interior of the cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/227—Driving means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0058—Liquid or visquous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings
    • B29K2105/101—Oriented
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present disclosure relates generally to a manufacturing system and, more particularly, to an additive manufacturing system implementing anchor curing.
  • FDM fused deposition modeling
  • a recently developed improvement over traditional FDM manufacturing involves the use of continuous fibers embedded within material discharging from the print head (a.k.a., Continuous Fiber 3D Printing - CF3DTM).
  • a matrix is supplied to the print head and discharged (e.g., extruded and/or pultruded) along with one or more continuous fibers also passing through the same head at the same time.
  • the matrix can be a traditional thermoplastic, a powdered metal, a liquid matrix (e.g., a UV curable and/or two-part resin), or a combination of any of these and other known matrixes.
  • a cure enhancer e.g., a UV light, an ultrasonic emitter, a heat source, a catalyst supply, etc.
  • a cure enhancer e.g., a UV light, an ultrasonic emitter, a heat source, a catalyst supply, etc.
  • This curing occurs almost immediately, allowing for unsupported structures to be fabricated in free space. And when fibers, particularly continuous fibers, are embedded within the structure, a strength of the structure may be multiplied beyond the matrix- dependent strength.
  • the cure enhancers described above are mounted directly to the print head.
  • relatively opaque fibers such as carbon fibers, high-density fibers, high-concentrations of fibers, large-diameter fibers, etc.
  • light from the cure enhancers can be blocked by the fibers during an anchoring procedure occurring at a start of a fabrication event. This can lead to the need for manual intervention and/or result in a delayed fabrication start and weak anchoring.
  • the disclosed system is directed to addressing one or more of the problems set forth above and/or other problems of the prior art.
  • the present disclosure is directed to a system for additively manufacturing a composite structure.
  • the system may include a print head configured to discharge a matrix- coated reinforcement, and a support configured to move the print head in multiple dimensions during discharging of the matrix-coated reinforcement.
  • the system may further include at least one cure enhancer located offboard the print head, and a controller in communication with the support and the at least one cure enhancer.
  • the controller may be configured to selectively activate the at least one cure enhancer to expose the matrix-coated reinforcement to a cure energy during discharging of the matrix-coated reinforcement.
  • the present disclosure is directed to another system for additively manufacturing a composite structure.
  • This system may include a print head configured to discharge a matrix-coated reinforcement, and at least one onboard cure enhancer operatively mounted to the print head.
  • the system may further include a support configured to move the print head in multiple dimensions during discharging of the matrix-coated reinforcement, and at least one offboard cure enhancer located offboard the print head.
  • the system may also include a controller in communication with the support, the at least one onboard cure enhancer, and the at least one offboard cure enhancer.
  • the controller may be configured to selectively activate the at least one onboard cure enhancer and the at least one offboard cure enhancer to expose the matrix- coated reinforcement to a cure energy during discharging of the matrix-coated reinforcement based on a proximity of the print head.
  • the present disclosure is directed to a method of additively manufacturing a composite structure.
  • the method may include discharging from a print head a matrix-coated reinforcement, and moving the print head in multiple dimensions during discharging of the matrix-coated reinforcement.
  • the method may further include selectively exposing the matrix-coated reinforcement to a cure energy from offboard the print head during discharging of the matrix-coated reinforcement.
  • FIG. 1 is a diagrammatic illustration of an exemplary disclosed manufacturing system. Detailed Description
  • Fig. 1 illustrates an exemplary system 10, which may be used to continuously manufacture a composite structure 12 having any desired cross-sectional shape (e.g., circular, polygonal, etc.).
  • System 10 may include at least a support 14 and a head 16.
  • Head 16 may have a body 18 that is coupled to and moved by support 14, and a nozzle 20 located at an opposing discharge end of body 18.
  • support 14 is a robotic arm capable of moving head 16 in multiple directions during fabrication of structure 12, such that a resulting longitudinal axis of structure 12 is three-dimensional. It is contemplated, however, that support 14 could alternatively be an overhead gantry or a hybrid gantry/arm also capable of moving head 16 in multiple directions during fabrication of structure 12.
  • a drive may mechanically couple head 16 to support 14, and may include components that cooperate to move and/or supply power or materials to head 16.
  • Body 18 may be configured to receive or otherwise contain a matrix.
  • the matrix may include any type of material (e.g., a liquid resin, such as a zero-volatile organic compound resin; a powdered metal; etc.) that is curable.
  • exemplary resins include thermosets, single- or multipart epoxy resins, polyester resins, cationic epoxies, acrylated epoxies, urethanes, esters, thermoplastics, photopolymers, polyepoxides, thiols, alkenes, thiol-enes, and more.
  • the matrix inside body 18 is pressurized, for example by an external device (e.g., an extruder or another type of pump - not shown) that is fluidly connected to head 16 via a corresponding conduit (not shown). In another embodiment, however, the pressure is generated completely inside of body 18 by a similar type of device. In yet other embodiments, the matrix is gravity-fed through and/or mixed within body 18. In some instances, the matrix may need to be kept cool and/or dark inside body 18 to inhibit premature curing; while in other instances, the matrix may need to be kept warm for the same reason. In either situation, body 18 may be specially configured (e.g., insulated, chilled, and/or warmed) to provide for these needs.
  • an external device e.g., an extruder or another type of pump - not shown
  • the pressure is generated completely inside of body 18 by a similar type of device.
  • the matrix is gravity-fed through and/or mixed within body 18. In some instances, the matrix may need to be kept cool and/or dark inside body 18 to inhibit premature
  • the matrix may be used to coat, encase, or otherwise surround any number of continuous reinforcements (e.g., separate fibers, tows, rovings, and/or sheets of material) and, together with the reinforcements, make up at least a portion (e.g., a wall) of composite structure 12.
  • the reinforcements may be stored within (e.g., on separate internal spools - not shown) or otherwise passed through body 18 (e.g., fed from external spools - not shown).
  • the reinforcements may be of the same type and have the same diameter and cross-sectional shape (e.g., circular, square, flat, etc.), or of a different type with different diameters and/or cross-sectional shapes.
  • the reinforcements may include, for example, carbon fibers, vegetable fibers, wood fibers, mineral fibers, glass fibers, metallic wires, optical tubes, etc. It should be noted that the term “reinforcement” is meant to encompass both structural and non- structural types of continuous materials that can be at least partially encased in the matrix discharging from nozzle 20.
  • the reinforcements may be exposed to (e.g., at least partially coated with) the matrix while the reinforcements are passing through body 18.
  • the matrix, dry reinforcements, and/or reinforcements that are already exposed to the matrix may be transported into body 18 in any manner apparent to one skilled in the art.
  • the matrix and reinforcement may be discharged from nozzle 20 as a track of composite material via at least two different modes of operation.
  • a first mode of operation the matrix and reinforcement are extruded (e.g., pushed under pressure and/or mechanical force) from nozzle 20, as head 16 is moved by support 14 to create the 3-dimensional shape of structure 12.
  • a second mode of operation at least the reinforcement is pulled from nozzle 20, such that a tensile stress is created in the reinforcement during discharge.
  • the matrix may cling to the reinforcement and thereby also be pulled from nozzle 20 along with the reinforcement, and/or the matrix may be discharged from nozzle 20 under pressure along with the pulled reinforcement.
  • a residual tension in the reinforcement may increase a strength of structure 12, while also allowing for a greater length of unsupported material to have a straighter trajectory (i.e., the tension may act against the force of gravity to provide free-standing support for structure 12).
  • the reinforcement may be pulled from nozzle 20 as a result of head 16 moving away from an anchor point 22.
  • a length of matrix- impregnated reinforcement may be pulled and/or pushed from nozzle 20, deposited onto anchor point 22, and cured, such that the discharged material adheres to anchor point 22.
  • head 16 may be moved away from anchor point 22, and the relative movement may cause the reinforcement to be pulled from nozzle 20.
  • the movement of reinforcement through body 18 could be assisted (e.g., via one or more internal and/or external feed mechanisms - not shown), if desired.
  • Anchor points 22 may extend from a build chamber (e.g., from a print bed or wall) 24 and/or from structure 12 itself. In fact, build chamber may 24, itself, function as an anchor point 22, if desired.
  • One or more cure enhancers may be selectively used to enhance a cure rate and/or quality of the matrix as it is discharged from head 16.
  • Cure enhancer 26 may be controlled to selectively expose internal and/or external surfaces of structure 12 to energy (e.g., UV light, electromagnetic radiation, vibrations, heat, a chemical catalyst, hardener, or initiator, etc.) during the formation of structure 12. The energy may increase a rate of chemical reaction occurring within the matrix, sinter the material, harden the material, or otherwise cause the material to cure as it discharges from head 16.
  • cure enhancers 26 may be cooperatively energized to produce a desired cure effect within structure 12.
  • multiple cure enhancers 26 are mounted proximate (e.g., within, on, and/or trailing from) head 16 (e.g., at a base of body 18, inside of body 18, outside of body 18, or otherwise adjacent nozzle 20) and energized continuously during discharge of material from nozzle 20.
  • at least one cure enhancer 26 is located offboard head 16 and associated with each (e.g., located on, inside of, adjacent to, etc.) anchor point 22. These offboard cure enhancer(s) may be used only during an initial step of a build process to help ensure proper adhesion to anchor point 22.
  • one or more additional offboard cure enhancers 26 are associated with build chamber 24, in which structure 12 is being fabricated.
  • one or more cure enhancers 26 may be mounted on, inside of, or behind a floor, wall, and/or ceiling of build chamber 24.
  • the associated surface of build chamber 24 may be generally transparent, and cure enhancer(s) 24 may be located at a side opposite print head 16, such that cure energy passes through the surface.
  • cure enhancers 26 may be selectively activated at any time during the build process (e.g., simultaneously and continuously throughout the process, or sequentially and temporarily based on a known or tracked proximity of head 16 during controlled movements by support 14) to help ensure a desired level of cure within structure 12.
  • any combination of head-mounted, anchor-mounted, and/or chamber-mounted cure enhancers 26 may be used at any time during fabrication of structure 12.
  • Each of these cure enhancers 26 may generate an equal amount of cure energy of the same type and having the same characteristics (e.g., angle, focus, intensity, wavelength, direction, etc.), or different amounts of cure energy of differing types and having different characteristics.
  • a controller 28 may be provided and communicatively coupled with support 14, head 16, and any number and type of cure enhancers 26. Controller 28 may embody a single processor or multiple processors that include a means for controlling an operation of system 10. Controller 28 may include one or more general- or special-purpose processors or microprocessors. Controller 28 may further include or be associated with a memory for storing data such as, for example, design limits, performance characteristics, operational instructions, matrix characteristics, reinforcement characteristics, characteristics of structure 12, and corresponding parameters of each component of system 10. Various other known circuits may be associated with controller 28, including power supply circuitry, signal-conditioning circuitry, solenoid/motor driver circuitry, communication circuitry, and other appropriate circuitry. Moreover, controller 28 may be capable of communicating with other components of system 10 via wired and/or wireless transmission.
  • One or more maps may be stored in the memory of controller 28 and used during fabrication of structure 12. Each of these maps may include a collection of data in the form of lookup tables, graphs, and/or equations. In the disclosed embodiment, the maps are used by controller 28 to determine desired characteristics of cure enhancers 26, the associated matrix, and/or the associated reinforcements at different locations within structure 12. The characteristics may include, among others, a type, quantity, and/or configuration of reinforcement and/or matrix to be discharged at a particular location within structure 12, and/or an amount, shape, timing, and/or location of desired curing.
  • Controller 28 may then correlate operation of support 14 (e.g., the location and/or orientation of head 16) and/or the discharge of material from nozzle 20 (a type of material, desired performance of the material, cross-linking requirements of the material, a discharge rate, etc.) with the operation of cure enhancers 26 such that structure 12 is produced in a desired manner.
  • support 14 e.g., the location and/or orientation of head 16
  • discharge of material from nozzle 20 a type of material, desired performance of the material, cross-linking requirements of the material, a discharge rate, etc.
  • the disclosed system may be used to continuously manufacture composite structures having any desired cross-sectional shape, length, density, and/or strength.
  • the composite structures may include any number of different reinforcements of the same or different types, diameters, shapes, configurations, and consists, and/or any number of different matrixes. Operation of system 10 will now be described in detail.
  • information regarding a desired structure 12 may be loaded into system 10 (e.g., into controller 28 that is responsible for regulating operation of support 14, cure enhancer(s) 26, and/or any other associated components).
  • This information may include, among other things, a size (e.g., diameter, wall thickness, length, etc.), a contour (e.g., a trajectory), surface features (e.g., ridge size, location, thickness, length; flange size, location, thickness, length; etc.), connection geometry (e.g., locations and sizes of couplings, tees, splices, etc.), location-specific matrix stipulations, location-specific reinforcement stipulations, desired cure rates, cure locations, cure shapes, cure amounts, etc.
  • a size e.g., diameter, wall thickness, length, etc.
  • a contour e.g., a trajectory
  • surface features e.g., ridge size, location, thickness, length; flange size, location, thickness, length; etc.
  • a specific cure enhancer configuration may be connected to head 16 (e.g., to the discharge end of body 18), to anchor point(s) 22, and/or various surfaces of build chamber 24, and one or more different (e.g., different sizes, shapes, and/or types of) reinforcements and/or matrixes may be selectively installed within system 10 and/or continuously supplied into nozzle 20.
  • the corresponding reinforcements may be passed through nozzle 20, and thereafter connected to a pulling machine (not shown) and/or to a mounting fixture (e.g., to anchor point 22). Installation of the matrix may include filling body 18 and/or coupling of an extruder (not shown) to head 16.
  • Head 16 may be moved by support 14 under the regulation of controller 28 to cause matrix-coated reinforcements to be placed against or on a corresponding anchor point 22.
  • Any combination of cure enhancers 26 e.g., the offboard cure enhancers 26 mounted to a particular anchor point 22 and/or the onboard cure enhancers 26 of head 16 ) may then be selectively activated (e.g., turned on by controller 28) to cause hardening of the matrix surrounding the reinforcements, thereby bonding the reinforcements to anchor point 22.
  • the component information may then be used to control operation of system 10.
  • the reinforcements may be pulled through body 18, submerged within the matrix, and then discharged from nozzle 20.
  • Controller 28 selectively cause support 14 to move head 16 in a desired manner at this time, such that an axis of the resulting structure 12 follows a desired trajectory (e.g., a free-space, unsupported, 3-D trajectory).
  • cure enhancers 26 associated with head 16 and/or build chamber 24 may be selectively activated by controller 28 during material discharge to initiate, speed up, or complete hardening of the matrix.
  • various chamber-mounted cure enhancers 26 may be selectively activated to provide a desired level of cure within the material.

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  • Manufacturing & Machinery (AREA)
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  • Composite Materials (AREA)
  • Health & Medical Sciences (AREA)
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  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Textile Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Moulding By Coating Moulds (AREA)
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