WO2023035004A1 - Tête d'impression pour système de fabrication additive - Google Patents

Tête d'impression pour système de fabrication additive Download PDF

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Publication number
WO2023035004A1
WO2023035004A1 PCT/US2022/075958 US2022075958W WO2023035004A1 WO 2023035004 A1 WO2023035004 A1 WO 2023035004A1 US 2022075958 W US2022075958 W US 2022075958W WO 2023035004 A1 WO2023035004 A1 WO 2023035004A1
Authority
WO
WIPO (PCT)
Prior art keywords
module
reinforcement
matrix
trailing
leading
Prior art date
Application number
PCT/US2022/075958
Other languages
English (en)
Inventor
Andrew John OVERBY
Nathan Andrew STRANBERG
Stephen Tyler WILSON
Sam Armstrong
Samuel VANDENBERG
Maxwell Joseph JOHNSON
Original Assignee
Continuous Composites Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US17/929,659 external-priority patent/US20230071473A1/en
Application filed by Continuous Composites Inc. filed Critical Continuous Composites Inc.
Publication of WO2023035004A1 publication Critical patent/WO2023035004A1/fr

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Classifications

    • 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
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • 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
    • B29C64/10—Processes of additive manufacturing
    • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
    • B29C64/194—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
    • 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
    • B29C64/205—Means for applying layers
    • B29C64/209—Heads; Nozzles
    • 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
    • B29C64/205—Means for applying layers
    • B29C64/214—Doctor blades
    • 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
    • B29C64/205—Means for applying layers
    • B29C64/218—Rollers
    • 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
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/321—Feeding
    • 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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

Definitions

  • the present disclosure relates generally to a manufacturing system and, more particularly, to a print head and method for an additive manufacturing system.
  • Continuous fiber 3D printing involves the use of continuous fibers embedded within material discharging from a moveable print head.
  • 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 print head at the same time.
  • the matrix can be a traditional thermoplastic, a liquid thermoset (e.g., an energy-curable single- or multi-part resin), or a combination of any of these and other known matrixes.
  • a cure enhancer e.g., a UV light, a laser, an ultrasonic emitter, a heat source, a catalyst supply, or another energy source
  • a cure enhancer e.g., a UV light, a laser, an ultrasonic emitter, a heat source, a catalyst supply, or another energy source
  • a cure enhancer e.g., a UV light, a laser, an ultrasonic emitter, a heat source, a catalyst supply, or another energy source
  • enhance, and/or complete curing e.g., crosslinking and/or hardening
  • CF3D ® provides for increased strength, compared to manufacturing processes that do not utilize continuous fiber reinforcement, care should be taken to ensure proper wetting of the fibers with the matrix, proper cutting of the fibers, automated restarting after cutting, proper compaction of the matrix-coated fibers after discharge, and proper curing of the compacting material.
  • Exemplary print heads that provide for at least some of these functions are disclosed in U.S. Patent Application Publication 2021/0260821 that was filed on February 24, 2021 (“the ’8215 publication”) and in U.S. Patent Application 17/443,421 that was filed on July 26, 2021 (“the ’421 application”), both of which are incorporated herein by reference.
  • the print heads of the 821 publication and the ’421 application may be functionally adequate for many situations, they may be less than optimal.
  • the print heads may lack accuracy in wetting, placement, cutting, compaction, curing and/or control that is required for other situations.
  • the disclosed print heads, methods and systems are directed at addressing one or more of these issues and/or other problems of the prior art.
  • the present disclosure is directed to a system for additively manufacturing an object.
  • the system may include a support and a print head operatively connected to and moveable by the support.
  • the print head may include an outlet configured to discharge a material, a leading device, and a trailing device 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.
  • the leading device is configured to provide a primary compacting force to the material
  • the trailing device is configured to provide a primary wiping function
  • the leading device is configured to roll over the material
  • the trailing device is configured slide over the material
  • the system further includes an actuator configured to move the leading and trailing devices together relative to the outlet.
  • the system further includes a first spring configured to urge only the trailing device to pivot towards the material.
  • system further includes a second spring configured to bias the leading and trailing devices together towards the material.
  • system further includes an arm pivotally connecting the trailing device to the leading device, wherein the trailing device is removably connected to the arm via a keyway.
  • the system further includes at least one cure enhancer connected to at least one of the leading and trailing devices and configured to expose the material to a cure energy.
  • the system further includes a frame connecting the at least one cure enhancer to the leading device, and an actuator configured to move the at least one cure enhancer together with both of the leading and trailing devices via the frame.
  • the system further includes a spring configured to bias the leading and trailing devices relative to the at least one cure enhancer.
  • the at least one cure enhancer is held within the frame in a fastener-less manner.
  • the leading device has an outer surface that is rigid and configured to maintain its shape when engaging the material
  • the trailing device has an outer surface that is compliant and configured to deform when engaging the material
  • each of the leading and trailing devices has a non-deformed circular cross-section.
  • a diameter of the leading device is larger than a diameter of the trailing device.
  • the leading device includes a reinforcement guiding feature formed in an outer surface that engages the material.
  • the present disclosure is directed to another system for additively manufacturing an object.
  • This system may include a support and a print head operatively connected to and moveable by the support.
  • the print head may include an outlet configured to discharge a material, a leading device configured to engage and move over the material after discharge, a trailing device configured to engage and move over the material at a location trailing the leading device, and at least one cure enhancer configured to expose the material to a cure energy.
  • the system may also include a controller programmed to cause the support to move the print head during discharging of the material, and to steer a tool center point of the system along a target path having an axial trajectory in an x-direction.
  • the tool center point may have an x- location between a point of highest pressure exerted by the leading device and a leading edge of an engagement surface of the trailing device.
  • the x-location is outside of a pressure zone of the leading device.
  • the x-location is closer to the pressure zone than the leading edge of the engagement surface.
  • the tool center point has a y-location that falls within a plane encompassing an axis of the outlet.
  • the plane is a plane of symmetry passing through the leading and trailing devices.
  • the tool center point has a z -location that is 1 ⁇ 2 of a thickness of the material below a plane encompassing the engagement surface and tangent to the leading device.
  • the controller is further configured to maintain a 16 axis of the support normal to a print surface at the tool center point during material discharging.
  • the controller is further configured to maintain an axis of the leading device parallel to the print surface at the tool center point during material discharging.
  • the present disclosure is directed to a method for additively manufacturing an object.
  • the method may include discharging a material through an outlet of a print head, engaging and moving a leading device over the material after discharge, engaging and moving a trailing device over the material, and exposing the material to a cure energy.
  • the method may also include moving the print head during discharging of the material, and steering a tool center point of the print head along a target path having an axial trajectory in an x-direction.
  • the tool center point may have an x-location between a point of highest pressure exerted by the leading device and a leading edge of an engagement surface of the trailing device.
  • the tool center point has a y-location that falls within a plane encompassing an axis of the outlet, and the tool center point has a z-location that is 1 ⁇ 2 of a thickness of the material below a plane encompassing the engagement surface and tangent to the leading device.
  • the present disclosure is directed to a system for additively manufacturing an object.
  • the system may include a support and a print head operatively connected to and moveable by the support.
  • the print head may include a supply module configured to hold a reinforcement, and a wetting module.
  • the wetting module may include a body with an inlet configured to separately receive the reinforcement and a matrix, and an outlet configured to discharge the reinforcement wetted with the matrix.
  • the print head may also include a teasing mechanism disposed between the inlet and the outlet. The teasing mechanism may have multiple operating positions configured to affect varying levels of pressure against the reinforcement.
  • the print head includes a matrix source configured to direct pressurized matrix into the wetting module.
  • the system further includes a pressure sensor associated with the wetting module and configured to generate a pressure signal indicative of a matrix pressure inside of the wetting module.
  • the system further includes a controller programmed to selectively adjust a pressure of the matrix source based on the pressure signal.
  • the controller is programmed to selectively adjust a pressure of air directed into the matrix source based on a pressure of matrix inside the wetting module.
  • the controller is further programmed to make a comparison of air pressure to matrix pressure and selectively determine a characteristic of the matrix based on the comparison.
  • the characteristic is a quality.
  • the system further includes a temperature sensor configured to detect a temperature of the matrix in the wetting module, wherein the controller is configured to determine the quality of the matrix based further on the temperature.
  • the system further includes a heater configured to heat the matrix in the wetting module.
  • the heater is located upstream of the temperature sensor.
  • the characteristic is a viscosity
  • the controller is further programmed to make a comparison of air pressure to matrix pressure and selectively determine a determine a failure of the matrix source based on the comparison.
  • the teasing mechanism includes at least one roller configured to press the matrix through the reinforcement.
  • the teasing mechanism further includes a frame removeable from the wetting module and having a plurality of mounting positions for the at least one roller.
  • the at least one roller includes a plurality of rollers.
  • the present disclosure is directed to a method of additively manufacturing a structure.
  • the method may include pressurizing a matrix at a supply, and directing the pressurized matrix from the supply to an outlet that is remote from the supply.
  • the method may also include detecting a pressure at the outlet, and adjusting a pressure at the supply based on the pressure at the outlet.
  • the method may further include making a comparison of the pressure at the outlet to an expected pressure, and determining a characteristic of the matrix based on the comparison
  • the characteristic is a viscosity
  • the characteristic is a quality.
  • the method further includes sensing a temperature of the matrix at the outlet, wherein determining the quality includes determining the quality based further on the temperature.
  • the method further includes determining a failure of the supply based on the comparison.
  • the present disclosure is directed to a system for additively manufacturing an object.
  • the system may include a first module configured to discharge a composite material including a continuous reinforcement and a matrix, and a cutting module located downstream of the first module and configured to sever the continuous reinforcement discharging from the first module.
  • the cutting module may include a cutting mechanism configured to engage the continuous reinforcement, and a guide moveable to selectively abut the reinforcement during engagement of the reinforcement by the cutting mechanism.
  • the cutting mechanism is configured to bias the continuous reinforcement in at least a first direction during the engagement, and the guide is moveable to selectively abut a side of the continuous reinforcement to resist motion of the continuous reinforcement in at least the first direction.
  • the cutting module further includes a first actuator configured to rotate the cutting mechanism in a first rotational direction during the engagement, the at least a first direction being tangential to the first rotational direction.
  • the cutting module further includes a second actuator configured to translate the cutting mechanism towards the continuous reinforcement during rotation of the cutting mechanism.
  • translation of the cutting mechanism causes the guide to move and abut the continuous reinforcement.
  • system further includes a controller in communication with the first actuator and configured to selectively reverse rotational directions of the cutting mechanism.
  • the guide is selectively moveable to abut the continuous reinforcement at two opposing sides of the continuous reinforcement to resist motion of the continuous reinforcement caused by either of opposing rotational directions.
  • the guide is selectively moveable to abut the continuous reinforcement at two opposing sides of the continuous reinforcement.
  • the guide includes first and second arms that pivot towards opposing sides of the continuous reinforcement, and a distance between the first and second arms decreases as the cutting mechanism engages the continuous reinforcement.
  • the system further includes an actuator configured to rotate the cutting mechanism, wherein the first and second arms are connected to pivot about an axis of the actuator.
  • the system further includes a second module configured to compact the discharged composite material, and the cutting module is located between the first and second modules and configured to sever the continuous reinforcement passing from the first module to the second module.
  • the system further includes a first actuator configured to move the cutting module and at least the second module, and a second actuator configured to move the cutting mechanism relative to at least the second module.
  • the system further includes a third actuator configured to rotate the cutting mechanism.
  • the second actuator causes movement of guide simultaneous with movement of the cutting mechanism.
  • the present disclosure is directed to a method for additively manufacturing an object.
  • the method may include discharging a composite material, including a continuous reinforcement and a matrix, through a first module.
  • the method may further include engaging a cutting mechanism of a cutting module with the continuous reinforcement to sever the continuous reinforcement, and selectively abutting the continuous reinforcement with a guide during engagement of the continuous reinforcement by the cutting mechanism.
  • engagement of the cutting mechanism biases the continuous reinforcement in at least a first direction
  • selectively abutting the continuous reinforcement with a guide includes selectively abut a side of the continuous reinforcement to resist motion of the continuous reinforcement in at least the first direction
  • the system further includes rotating the cutting mechanism in a first rotational direction during the engagement, wherein the at least a first direction is tangential to the first rotational direction.
  • engaging the cutting mechanism with the continuous reinforcement includes translating the cutting mechanism towards the continuous reinforcement during rotation of the cutting mechanism, and translating the cutting mechanism causes the guide to move and abut the continuous reinforcement.
  • the system further includes selectively reversing rotational directions of the cutting mechanism
  • selectively abutting the continuous reinforcement with the guide includes selectively abutting the continuous reinforcement at two opposing sides of the continuous reinforcement to resist motion of the continuous reinforcement caused by either of opposing rotational directions.
  • the present disclosure is directed to a nozzle for an additive manufacturing print head.
  • the nozzle may include a body having a central passage with an entrant end and an exit end, and a shoulder protruding radially outward from the body at a location between the entrant and exit ends.
  • a groove may be formed within an outer surface of the body at a location between the shoulder and the entrant end. The groove may be configured to receive a seal.
  • the shoulder has an outer diameter greater than an outer diameter of the body at opposing sides of the shoulder.
  • the body is fabricated from stainless steel.
  • the entrant end of the central passage has an internal diameter that is 2- 5 times larger than an internal diameter at the exit end of the central passage.
  • the entrant end tapers to a smaller diameter at an internal location.
  • an angle of the taper is about 30-60°.
  • the exit end tapers from a smaller diameter at an internal location.
  • an angle of the taper at the exit end is about 30-60°.
  • the central passage includes a taper at a location between the entrant and exit tapers.
  • the taper of the central passage has an angle of about 30-45°
  • the body has a ratio of an internal diameter at the entrant end to an internal diameter at the exit end that is less than 3.5.
  • the body has a ratio of depth of the central passage to inner diameter of the central passage that is about 7 to 15, excluding any tapers at the entrant and exit ends.
  • the present disclosure is directed to a wetting module for an additive manufacturing system.
  • the wetting module may include a body having a central passage open along a side, an inlet to the central passage that is configured to receive a material, an outlet for the passage that is configured to discharge the material.
  • the wetting module may also include at least one nozzle disposed at least partially inside the body, and a lid configured to close off the side of the central passage and axially position the at least one nozzle.
  • the at least one nozzle includes a plurality of nozzles, and the lid is configured to axially position the plurality of nozzles.
  • the plurality of nozzles includes an upstream nozzle having a shoulder at a downstream end, and a downstream nozzle having a shoulder at a location between an upstream end and a downstream end.
  • the downstream nozzle has a protrusion that extends away from the shoulder in a downstream direction.
  • the lid includes positioning protrusions that engage the shoulders of the upstream and downstream nozzles.
  • the lid includes at least one positioning protrusion that engages the at least one nozzle to axially position the at least one nozzle.
  • the at least one positioning protrusion includes spaced apart tines.
  • the tines are tapered, such that further closing of the lid pushes the at least one nozzle further into engagement with the body.
  • the nozzle includes a body having a central passage with an entrant end and an exit end, and a shoulder protruding radially outward from the body of the nozzle at a location between the entrant and exit ends.
  • the wetting module further includes a seal positioned around the body at a location between the shoulder and the entrant end.
  • the present disclosure is directed to a method for additively manufacturing a structure.
  • the method may include discharging from a print head a first layer of material inward of an outer boundary of the structure.
  • the method may also include discharging from the print head a second layer of material adjacent the first layer and cantilevering past an edge of the first layer.
  • the method may further include compacting a portion of the second layer of material cantilevered past the edge of the first layer to extend into and form a portion of the first layer of material.
  • discharging from the print head the first layer of material includes discharging a plurality of adjacent paths of material into the first layer.
  • discharging from the print head the second layer of material includes discharging a plurality of adjacent paths of material into the second layer, and the plurality of adjacent paths of material in the second layer are generally parallel with the plurality of adjacent paths of material in the first layer.
  • discharging the plurality of adjacent paths of material into the second layer includes cantilevering at least one of the plurality of adjacent paths of material in the second layer by a distance of about 1/4th to 1 ⁇ 2 of a width of the at least one of the plurality of adjacent paths of material in the second layer.
  • compacting the portion of the second layer of material includes moving a deformable compaction device over the second layer of material.
  • moving the deformable compaction device over the second layer of material includes pressing the deformable compaction device against the second layer with a force sufficient to cause the deformable compaction device to deform and push the portion of the second layer of material cantilevered past the edge of the first layer to extend into and form the portion of the first layer of material.
  • the method further includes exposing the first layer of material to a cure energy prior to discharging from the print head the second layer of material adjacent the first layer.
  • the method further includes exposing the second layer of material to a cure energy.
  • compacting the portion of the second layer of material includes compacting the portion of the second layer of material prior to exposing the second layer of material to the cure energy.
  • compacting the portion of the second layer of material cantilevered past the edge of the first layer to extend into and form a portion of the first layer of material causes the first layer of material to grow up to the outer boundary.
  • the present disclosure is directed to a system for additively manufacturing an object.
  • This system may include a support, and a print head connected to and moveable by the support.
  • the print head may include an outiet configured to discharge a material to form an object, and a compacting device configured to move over and compact the material.
  • the print head may also include at a least a first transmitter configured to expose the compacted material to a cure energy, and at a least second transmitter trailing the at least a first transmitter and being configured to expose the compacted material to additional energy.
  • the at least a second transmitter may be located a greater distance away from the compacted material than the at least a first transmitter.
  • the system further includes a bracket mounting the at least a first transmitter and the at least a second transmitter to the compacting device.
  • the print head further includes a seal configured to retain the at least a first transmitter in the bracket.
  • the bracket is generally C-shaped, having a spine and two legs that extend in a same direction from opposing ends of the spine, and the at least a first transmitter includes two transmitters, one mounted in each of the two legs.
  • the at least a second transmitter also includes two transmitters, one mounted in each of the two legs.
  • the two transmitters are inclined in a first direction such that outlets of the two transmitters are located closer to a center plane of symmetry of the bracket than the two legs in which the two transmitters are mounted.
  • an incline angle in the first direction between the two transmitters is about 50-120°.
  • the two transmitters are tilted in a second direction orthogonal to the first direction, such that the outlets of the two transmitters are closer to the compacting device.
  • the at least a second transmitter also includes two transmitters, one mounted in each of the two legs at trailing locations, and the two transmitters of the at least a second transmitter are tilted by a greater amount in the second direction compared to the two transmitters of the at least a first transmitter.
  • the system further includes an actuator mounted between the two transmitters, and a cutting mechanism connected to the actuator.
  • FIG. 1 is a diagrammatic illustration of an exemplary disclosed additive manufacturing system
  • FIGs. 2, 3, 4 and 5 are diagrammatic illustrations of an exemplary disclosed print head (head) that may be utilized with the additive manufacturing system of Fig. 1;
  • Figs. 6A, 6B, 7, 8, 9 and 10 are cross-sectional and/or diagrammatic illustrations of exemplary disclosed reinforcement supply, tensioning, matrix supply, and compacting/curing modules that may be used in conjunction with the head of Figs. 2-5;
  • FIGs. 11 and 12 are diagrammatic illustrations of exemplary portions of the head of Figs. 2-5;
  • Figs. 13, 14, 15, 16, 17, 18, 19, 20 and 21 are cross-sectional and/or diagrammatic illustrations of an exemplary disclosed wetting module that may be used in conjunction with the head of Figs. 2-5;
  • Figs. 22, 23, 24, 25, 26, 27, 28, 29, 30, 31 and 32 are cross-sectional and/or diagrammatic illustrations of exemplary disclosed components of the wetting module of Figs. 13- 21;
  • Figs. 33, 34 and 35 are cross-sectional and diagrammatic illustrations of another exemplary disclosed wetting module that may be used in conjunction with the head of Figs. 2-5;
  • Figs 36 and 37 are cross-sectional illustrations of exemplary disclosed components of the wetting module of Figs. 33-35;
  • Figs. 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62 and 63 are cross-sectional and/or diagrammatic illustrations of an exemplary disclosed compacting/curing module that may be used in conjunction with the head of Figs. 2-5;
  • Fig. 64 is a diagram illustrating exemplary disclosed operations that may be performed by the additive manufacturing system of Fig. 1;
  • Figs. 65, 66 and 67 are cross-sectional and/or diagrammatic illustrations of an exemplary disclosed compacting/curing module that may be used in conjunction with the head of Figs. 2-5;
  • Figs. 68, 69, 70 and 71 are diagrammatic illustrations of exemplary portions of the head of Figs. 2-5;
  • Figs. 72, 73 and 74 are diagrammatic illustrations of exemplary disclosed processes that may be performed by the additive manufacturing system of Fig. 1.
  • substantially refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.
  • Fig. 1 illustrates an exemplary system 10, which may be used to manufacture a composite structure 12 having any desired shape, size, configuration, and/or material composition.
  • System 10 may include at least a support 14 and a print head (“head”) 16.
  • Head 16 may be coupled to and moveable by support 14 during discharge of a composite material (shown as C).
  • support 14 is a robotic arm capable of moving head 16 in multiple directions during fabrication of structure 12.
  • Support 14 may alternatively embody a gantry (e.g., a floor gantry, an overhead or bridge gantry, a single-post gantry, etc.) or a hybrid gantry/arm also capable of moving head 16 in multiple directions during fabrication of structure 12.
  • gantry e.g., a floor gantry, an overhead or bridge gantry, a single-post gantry, etc.
  • hybrid gantry/arm also capable of moving head 16 in multiple directions during fabrication of structure 12.
  • a drive or coupler 18 may mechanically join head 16 to support 14 and include components that cooperate to move portions of and/or supply power and/or materials to head 16.
  • Head 16 may be configured to receive or otherwise contain a matrix that, together with a continuous reinforcement (e.g., with or without other additives or fillers), makes up the composite material C discharging from head 16.
  • the matrix may include any type of material that is curable (e.g., a liquid resin, such as a zero-volatile organic compound resin, a powdered metal, etc.).
  • exemplary resins include thermosets, single- or multi-part epoxy resins, polyester resins, cationic epoxies, acrylated epoxies, urethanes, esters, thermoplastics, photopolymers, polyepoxides, thiols, alkenes, thiol-enes, and more.
  • the matrix inside head 16 may be pressurized, for example by an external device (e.g., by 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 may be generated completely inside of head 16 by a similar type of device (discussed in more detail below). In yet other embodiments, the matrix may be gravity-fed into and/or through head 16. For example, the matrix may be fed into head 16 and pushed or pulled out of head 16 along with one or more continuous reinforcements. In some instances, the matrix inside head 16 may benefit from being kept cool, dark, and/or pressurized (e.g., to inhibit premature curing or otherwise obtain a desired rate of curing after discharge). In other instances, the matrix may need to be kept warm and/or light for similar reasons. In either situation, head 16 may be specially configured (e.g., insulated, temperature- controlled, shielded, etc.) to provide for these needs.
  • head 16 may be specially configured (e.g.
  • the matrix may be used to coat any number of continuous reinforcements (e.g., separate fibers, tows, rovings, ribbons, socks, sheets and/or tapes of continuous material) and, together with the reinforcements, make up a portion (e.g., a wall) of composite structure 12.
  • the reinforcements may be stored within (e.g., on one or more separate internal creels 19) or otherwise passed through head 16 (e.g., fed from one or more external spools - not shown).
  • the reinforcements may be of the same material composition and have the same sizing and cross-sectional shape (e.g., circular, square, rectangular, etc.), or of a different material composition with different sizing 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 are at least partially encased in the matrix discharging from head 16.
  • the reinforcements may be exposed to (e.g., at least partially coated with) the matrix while the reinforcements are inside head 16, while the reinforcements are being passed to head 16, and/or while the reinforcements are discharging from head 16.
  • the matrix, dry reinforcements, and/or reinforcements that are already exposed to the matrix may be transported into head 16 in any manner apparent to one skilled in the art.
  • a filler material e.g., chopped fibers, particles, nanotubes, etc.
  • one or more cure enhancers may be mounted proximate (e.g., within, on, or adjacent) head 16 and configured to enhance a cure rate and/or quality of the matrix as it discharges from head 16.
  • the cure enhancers may be controlled to selectively expose portions of structure 12 to the cure energy (e.g., to UV light, electromagnetic radiation, vibrations, heat, a chemical catalyst, etc.) during material discharge and the formation of structure 12.
  • the cure energy may trigger a chemical reaction to occur within the matrix, increase a rate of the chemical reaction, sinter the matrix, harden the matrix, or otherwise cause the matrix to cure as it discharges from head 16.
  • the amount of energy produced by the cure enhancers may be sufficient to cure the matrix before structure 12 axially grows more than a predetermined length away from head 16.
  • structure 12 is at least partially cured before the axial growth length becomes equal to a cross-sectional dimension of the matrix-coated reinforcement.
  • the matrix and/or reinforcement may be discharged from head 16 via one or more different modes of operation.
  • the matrix and/or reinforcement are extruded (e.g., pushed under pressure and/or mechanical force) from head 16 as head 16 is moved by support 14 to create the 3-dimensional trajectory within a longitudinal axis of the discharging material.
  • a second exemplary mode of operation at least the reinforcement is pulled from head 16, 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 head 16 along with the reinforcement, and/or the matrix may be discharged from head 16 under pressure along with the pulled reinforcement.
  • the resulting tension in the reinforcement may increase a strength of structure 12 (e.g., by aligning the reinforcements, inhibiting buckling, disbursing loading, etc.), while also allowing for a greater length of unsupported structure 12 to have a straighter trajectory. That is, the tension in the reinforcement remaining after curing of the matrix may act against the force of gravity (e.g., directly and/or indirectly by creating moments that oppose gravity) to provide support for structure 12.
  • the reinforcement may be pulled from head 16 as a result of head 16 being moved by support 14 away from an anchor (e.g., a print bed, a table, a floor, a wall, an existing surface of structure 12, etc.).
  • an anchor e.g., a print bed, a table, a floor, a wall, an existing surface of structure 12, etc.
  • a length of matrix- impregnated reinforcement may be pulled and/or pushed from head 16, deposited against the anchor, and at least partially cured, such that the discharged material adheres (or is otherwise coupled) to the anchor.
  • head 16 may be moved away from the anchor (e.g., via controlled regulation of support 14), and the relative movement may cause the reinforcement to be pulled from head 16.
  • the movement of reinforcement through head 16 could be assisted (e.g., via one or more internal feed mechanisms), if desired.
  • the discharge rate of reinforcement from head 16 may primarily be the result of relative movement between head 16 and the anchor, such that tension is created within the reinforcement.
  • the anchor could be moved away from head 16 instead of or in addition to head 16 being moved away from the anchor.
  • a controller 20 may be provided and communicatively coupled with support 14, head 16, and any number of the cure enhancers). Each controller 20 may embody a single processor or multiple processors that are specially programmed or otherwise configured via software and/or hardware to control an operation of system 10. Controller 20 may further include or be associated with a memory for storing data such as, for example, design limits, performance characteristics, operational instructions, tool paths, and corresponding parameters of each component of system 10. Various other known circuits may be associated with controller 20, including power supply circuitry, signal-conditioning circuitry, solenoid driver circuitry, communication circuitry, and other appropriate circuitry. Moreover, controller 20 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 20 and used by controller 20 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.
  • controller 20 may be specially programmed to reference the maps and determine movements/operations of head 16 required to produce the desired size, shape, and/or contour of structure 12, and to responsively coordinate operation of support 14, the cure enhancer(s), and other components of head 16.
  • head 16 may include a mounting arrangement that is configured to hold, enclose, contain, and/or otherwise provide mounting for the remaining components of head 16.
  • the mounting arrangement may include an upper generally horizontal plate 24 (e.g., upper plate as viewed from the perspective of Figs. 2-5) and one or more generally vertical plates 26 (e.g., lower plates) that intersect orthogonally with upper plate 24.
  • the other components of head 16 may be mounted to a front and/or back of lower plate(s) 26 and/or to a top or bottom side of upper plate 24.
  • some components may extend downward past a terminal end of lower plate(s) 26.
  • some components may extend transversely from lower plate(s) 26 past outer edges of upper plate 24.
  • Upper plate 24 may be generally rectangular (e.g., square), while lower plate 26 may be elongated and/or tapered to have a triangular shape. Lower plate 26 may have a wider proximal end rigidly connected to a general center of upper plate 24 and a narrower distal end that is cantilevered from the proximal end.
  • Coupler 18 may be connected to upper plate 24 at a side opposite lower plate(s) 26 and used to quickly and releasably connect head 16 to support 14.
  • One or more racking mechanisms e.g., handles, hooks, eyes, etc. - not shown
  • any number of components of head 16 may be mounted to upper and/or lower plates 24, 26.
  • a reinforcement supply module 44 and a matrix supply module 46 may be operatively connected to upper plate 24, while a tensioning module 48, a clamping module 50, a wetting module 52, a cutting module 56, and a compacting/curing module 58 may be operatively mounted to lower plate(s) 26.
  • the reinforcement may pay out from module 44, pass through and be tension-regulated by module 48, and thereafter be wetted with matrix in and discharged through module 52 (e.g., as supplied by module 46). After discharge, the matrix-wetted reinforcement may be selectively severed via module 56 (e.g., while being held stationary by module 50) and thereafter compacted and/or cured by module 58.
  • the mounting arrangement may also include an enclosure 54 configured to protect particular components of head 16 from inadvertent exposure to matrix, solvents, and/or other environmental conditions that could reduce usage and/or a lifespan of these components.
  • these components may include, among others, any number of conduits, valves, actuators, chillers, heaters, manifolds, wiring harnesses, sensors, drivers, controllers, input devices (e.g., buttons, switches, etc.), output devices (e.g., lights, speakers, etc.) and other similar components.
  • Module 44 may be a subassembly that includes components configured to selectively allow and/or drive rotation of creel 19 and the corresponding payout of reinforcement.
  • the rotation of creel 19 may be regulated by controller 20 (referring to Fig. 1) based, at least in part, on a detected position of module 48.
  • This rotational regulation may help to maintain one or more desired levels of tension within the reinforcement. For example, a nominal tension may be desired during normal material discharge; a higher or lower level of tension may be desired during free-space printing; and a higher level of tension may be desired during severing of the discharging material, and controller 20 may selectively implement these tensions based on detection of the corresponding operations.
  • module 44 may be a subassembly that includes components configured to selectively allow and/or drive rotation of creel 19.
  • components may include, among other things, a rotating actuator 62 operatively connecting creel 19 to at least one of upper and lower plates 24, 26 (e.g., to only lower plate 26).
  • controller 20 may selectively activate rotating actuator 62 to cause creel 19 to rotate and pay out reinforcement from a spool 78.
  • rotating actuator 62 may include a rotor 76 rotationally affixed to creel 19.
  • spool 78 may be easily removed (e.g., slipped axially off) from creel 19 and rotationally locked to rotor 76 (e.g., via a keyway, a friction device, etc.).
  • Rotor 76 may be rotationally supported by lower plate 26 (or another parallel plate) via one or more bearings 79.
  • a quick-release mechanism 80 may be used to releasably connect spool 78 to creel 19 and to the rest of module 44.
  • Spool 78 may include, among other things, a central core 82 configured to slide over and be received by creel 19, and one or more continuous reinforcements R wrapped around core 82.
  • Mechanism 80 may include a flange 84 fixedly connected to an end of creel 19 opposite rotor 76 (e.g., via one or more fasteners and/or pins 86) and having an outer diameter less than an inner diameter of core 82.
  • One or more tabs 88 may be moveably mounted to rotor 76, biased radially outward (e.g., via one or more springs 90), and manually and temporarily moved radially inward during installation.
  • tab(s) 88 When tab(s) 88 are moved inward, core 82 may pass uninhibited by mechanism 80 over the end of creel 19.
  • tab(s) 88 When tab(s) 88 are biased outward, tab(s) 88 may extend radially over at least a portion of (e.g., a rim) of core 82 to block spool 78 from inadvertently disengaging from creel 19.
  • Tab(s) 88 may slide within a channel 92 (e.g., in opposite directions) and include an inner end and an outer end.
  • a fingerhold 94 may extend axially outward (i.e., relative to an axis of creel 19) from the inner end of each tab 88.
  • Spring 90 may be disposed within channel 92, between the inner ends.
  • the outer end of each tab 88 may be chamfered in the axial direction of creel 19, which may cause tab 88 to move radially inward against the bias of spring 90 in response to axial engagement with core 82 (e.g., only during loading).
  • module 48 may be a subassembly located between modules 44 and 50 (e.g., relative to the travel of reinforcement through head 16) and include components configured to affect an amount and/or rate of the reinforcement being paid out by module 44 to module 50.
  • These components may include, among other things, a swing arm 98 pivotally connected at one end (e.g., an end closest to module 44) to lower plate 26 via a pivot shaft 100, a redirect 102 rotatably mounted at each end of swing arm 98, and a rotary sensor (e.g., encoder, potentiometer, etc.) 104 (shown only in Fig.
  • swing arm 98 may not be balanced about shaft 100. If unaccounted for, this imbalance could cause swing arm 98 to function differently as head 16 is tilted to different angles during operation. Accordingly, in some applications, a counterweight 108 may be connected to or integrally formed with swing arm 98 at a side opposite the free end of swing arm 98.
  • swing arm 98 may be biased (e.g., via one or more springs 106) toward an end or neutral position.
  • Spring 106 may extend from one or more anchors on lower plate 26 to an end of counterweight 108 or arm 98 (e.g., a lower end located away from plate 24).
  • spring 106 is a tension spring. It is contemplated, however, that a single torsion spring mounted around pivot shaft 100 could alternatively be utilized to bias swing arm 98, if desired.
  • swing arm 98 may be caused to rotate clockwise (e.g., relative to the perspective of Fig. 7) to provide a generally constant tension within the reinforcement. This rotation may result in a similar input rotation to sensor 104, which may responsively generate an output signal directed to controller 20 indicative of the increasing rate, tension, and/or tilt angle/position of swing arm 98.
  • the signal may be directed to module 44 (e.g., directly or via controller 20), causing an increased payout (e.g., increased speed and/or amount of payout) of the reinforcement from creel 19. This increased payout may, in turn, allow swing arm 98 to return towards its nominal position.
  • a desired range of tension within the reinforcement may be about 0-51bs (e.g., about 0-llb).
  • spring 106 may rotate swing arm 98 in the counterclockwise direction to provide the generally constant tension within the reinforcement.
  • sensor 104 may again generate a signal indicative of the rotation, tension, arm tilt angle/position, etc. and direct this signal to controller 20 for further processing and control over module 44 (e.g., to cause a slowing payout of the reinforcement).
  • controller 20 may process this signal and control module 44 via P, PI, PID, and/or other control methodologies, as desired.
  • One or more end-stops 109 may be associated with module 48 to limit a range of rotation of swing arm 98.
  • two different end-stops are provided, including a hard end-stop 109a and a high-tension end stop 109b.
  • Swing arm 98 may naturally rest against hard end stop 109a due to the bias of spring 106. Swing arm 98 be selectively driven into high-tension end stop 109b during one or more operating events (e.g., a severing event).
  • Module 46 may be configured to direct a desired amount of matrix at a specified rate, temperature, viscosity, and/or pressure to module 52 for wetting of the reinforcements received from module 44 via module 48.
  • module 46 may be an assembly of components that receive, condition and/or meter out matrix from a disposable cartridge 110.
  • Cartridge 110 may include, among other things, a tubular body 114, a cap 116 configured to close a base end of body 114, and a restricted outlet 118 located at an opposing tip end.
  • the matrix inside body 114 may be selectively pressed through outlet 118 by axially translating cap 116 through body 114 towards outlet 118.
  • a pressure-regulated medium e.g., air
  • the matrix discharging from outlet 118 may be directed through a port 126 toward module 52.
  • a pressure and/or a flow rate of the medium into cartridge 110 may correspond with an amount and/or a flow rate of matrix out of cartridge 110.
  • a linear actuator rather than the pressurized medium, may be used to push against cap 116, if desired.
  • controller 20 may implement P, Pl, PID, and/or other control methodologies to regulate the flow of matrix from cartridge 110, as desired.
  • a sensor 132 may be associated with cartridge 110 and configured to generate a signal indicative of an amount of matrix consumed from and/or remaining within cartridge 110.
  • sensor 132 is an optical sensor (e.g., a laser sensor) configured to generate a beam 134 directed to cap 116 from the base end of cartridge 110. Beam 134 may reflect off cap 116 and be received back at sensor 132, wherein a comparison of outgoing and incoming portions of beam 134 produces a signal indicative of the consumed and/or remaining matrix amount.
  • the signal may be used to generate an alert to a user of system 10, allowing the user to adjust operation (e.g., to pause or halt operation, park print head 16, swap out print heads 16, etc.), as desired.
  • another type of sensor e.g., a magnetic sensor, an acoustic sensor, etc.
  • a magnetic sensor e.g., an acoustic sensor, etc.
  • one or more seals 128 may be located at the base end of cartridge 110, adjacent a mounting plate 136.
  • Sensor 132 may be a standalone sensor having a nipple through which beam 134 is directed.
  • a plate of transparent material may separate the nipple from cartridge 110, such that sensor 132 is protected from internal pressures and resin contamination.
  • Beam 134 may pass through the transparent material substantially uninterrupted, such that an optical path is created to cap 116.
  • Compliant material around the transparent material may function as seal 128, thereby prolonging a life of sensor 132.
  • cartridge 110 may be light-sensitive. Accordingly, care should be taken to avoid exposure that could cause premature curing.
  • cartridge 110 may be opaque, transparent and tinted, coated (internally and/or externally), or otherwise shielded to inhibit light infiltration.
  • module 46 may be selectively heated, cooled, and/or insulated accordingly to one or more predetermined requirements of a particular matrix packaged within cartridge 110.
  • one or more heating elements e.g., electrodes - not shown
  • Controller 20 may be in communication with the heating elements) and configured to selectively adjust an output of the heating element(s) based on a known and/or detected parameter of the matrix in module 46 and/or within other portions of head 16.
  • Cartridge 110 may be mounted in a way that allows simple and quick removal from head 16 and replacement upon depletion of the matrix contained therein.
  • a retainer 138 embodying a cap may threadingly engage a vessel 112 (referring to Fig. 9) configured to hold cartridge 110.
  • port 126 may be rotatably mounted in retainer 138 and threadingly engaged with outlet 118 of cartridge 110.
  • clamping module 50 may primarily be configured to selectively clamp the reinforcement R and thereby inhibit movement (e.g., any movement or only reverse movement) of the reinforcement through head 16. This may be helpful, for example, during severing of the reinforcement away from structure 12, such that tensioning module 48 does not unintentionally pull the reinforcement back through head 16 after the reinforcement is separated from structure 12. This may also be helpful during off-structure movements of head 16 (e.g., when no reinforcement should be paying out) and/or briefly at a start of a new payout (e.g., while tacking the reinforcement at the anchor). In each of these scenarios, clamping module 50 may selectively function as a check-valve, ensuring unidirectional movement of the reinforcement through head 16. By allowing at least some movement of the reinforcement at all times, damage to the reinforcement may be reduced.
  • movement e.g., any movement or only reverse movement
  • clamping module 50 may include components that cooperate to perform multiple different clamping functions at the same or different times.
  • module 50 may include a first clamping subassembly 50A having jaws extending in a first direction (e.g., a first direction that is transverse to a travel direction of fiber through head 16), and a second clamping subassembly 50B having jaws extending in a second direction opposite the first direction.
  • the first clamping subassembly 50A may be selectively activated by controller 20 to clamp onto the reinforcement passing into module 52 (e.g., as shown in Fig. 11) and thereby inhibit relative motion between the reinforcement and module 52.
  • the second clamping mechanism 50B may be selectively activated to clamp onto a supply line extending from module 46 to module 52 and thereby inhibit matrix flow into module 52.
  • second clamping mechanism 50B may include a lip that protrudes from an end of a lower jaw, upward past a side of the supply line to retain the supply line within the jaws of second clamping module 50B.
  • first and second subassemblies 50A, 50B may be independently activated via separate actuators. In the disclosed embodiment, these actuators are pneumatically operated. It is contemplated, however, that these actuators may be hydraulically and/or electrically operated, if desired.
  • module 50 may be mounted to move together with module 52, relative to a rest of head 16. This movement may occur, for example, before, during, and/or after a severing event (e.g., after completion of a print path, during rethreading and/or during start of a new print path).
  • Modules 50 and 52 may be rigidly connected to each other via a bracket 192 that translates (e.g., rolls and/or slides linearly) along a rail 193 (shown in Fig. 13) that is affixed to lower plate 26.
  • Modules 50 and 52 may be located at a first side of lower plate 26, and rail 193 may be located at a second side of lower plate 26.
  • An actuator 197 (shown only in Fig. 4) may be mounted to lower plate 26 at the second side and mechanically linked to an end of bracket 192. With this configuration, an extension or retraction of actuator 197 may result in translation of bracket 192, module 50 and module 52 along a length of rail 193.
  • the reinforcement passing through modules 50, 52 may remain stationary or translate, depending on an actuation status of module 50 (e.g., of subassembly 50A). For example, when module 50 is active and clamping the reinforcement at a time of translation, the reinforcement may translate together with modules 50 and 52.
  • a tension within the reinforcement may function to hold the reinforcement stationary, move the reinforcement in a direction opposite the translation, or move the reinforcement in the same direction of the translation at a different speed.
  • a sensor 199 (shown in Fig. 13) may be associated with bracket 192 (e.g., disposed between lower plate 26 and bracket 192) to track the motion of modules 50, 52 and/or the payout of reinforcement.
  • Sensor 199 may include, for example, a sensing component that is stationarily mounted to lower plate 26 and an indexing component (e.g., a magnet) mounted to bracket 192, or vice versa.
  • Module 52 may be connected to bracket 192 via an adapter 194 (shown in Fig. 14).
  • Adapter 194 may connect to bracket 192 and to module 52 via one or more additional fasteners (not shown).
  • additional fasteners not shown.
  • locating features e.g., dowels, pins, recesses, slots, etc. may be used to align adapter 194 with module 52 and/or bracket 192 before fastening, if desired.
  • adapter 194 may be generally platelike, having an internal face 202 configured to mate against a side of module 52 (shown in Fig. 15), and an external face 204 located opposite module 52. Any number of ports may pass from face 204 through adapter 194 to face 202, and a seal 206 may be located at face 202 to seal around these ports.
  • At least one inlet port 212 may allow pressurized matrix from module 46 to pass through adapter 194 into module 52, and at least one outlet port 210 may allow excess or overflow matrix to drain or be pumped out of module 52 through adapter 194.
  • two outlet ports 210 are included and located at opposing sides of inlet port 212 (e.g., at lengthwise ends of module 52).
  • one or both of outlet ports 210 could selectively be utilized as an inlet port, if desired (e.g., matrix may be pulled from one port, depending on gravity, and pushed back into module 52 via the remaining port - see Fig. 21).
  • An additional port 208 may function as a sensing port to allow any adapter-mounted sensor(s) (e.g., a temperature sensor, a pressure sensor, etc. - see Figs. 16, 17 and 21) 214 to sense a characteristic of the matrix inside of module 52.
  • a passthrough interface (e.g., a male interface) 216 may also be mounted to adapter 194 to allow for electrical connections with other components) (e.g., a heater, a sensor, etc.) mounted inside of module 52 (e.g., via a corresponding female interface 218 on module 52- shown in Fig. 15).
  • a plate 220 shown in Fig.
  • adapter 194 may close off face 202 to inhibit curing of matrix within ports 208, 210, 212. While adapter 194 is shown as separate from bracket 192 (e.g., for manufacturing purposes), it is contemplated that adapter 194 could be integral with bracket 192, if desired.
  • wetting module 52 may include an elongated (e.g., elongated in a direction of reinforcement motion through module 52) base 152 having a fiber inlet end 154 and a matrix outlet end 156.
  • a lid 158 may be pivotally or otherwise removably connected to base 152 via one or more (e.g., two) hinges 160 located at a side adjacent adapter 194.
  • a seal 161 may be disposed between base 152 and lid 158, and any number of fasteners (or quick release or toolless mechanisms) 162 may connect lid 158 to base 152 at one or more locations (e.g., spaced apart at a side opposite hinges 160).
  • Lid 158 may be configured to pivot or otherwise be moved from a closed or operational position (shown in Figs. 15 and 17) to an open or servicing (e.g., threading/cleaning) position (shown in Fig. 19).
  • Base 152 and/or lid 158 may include one or more features 164 for mounting module 52 to the rest of head 16.
  • Features 164 may include, for example, bosses, holes, recesses, threaded bores and/or studs, dowels, etc. The number and locations of features 164 may be selected based on a weight, size, material, and/or balance of module 52.
  • base 152 and lid 158 may together form an elongated enclosure that tapers towards outlet end 156.
  • This tapering may reduce a formfactor of module 52, allowing a greater geometrical range of structure 12 (e.g., geometry having smaller internal angles) to be fabricated by system 10.
  • the taper may be formed via a single surface of base 152 tapering toward the plane of lid 158 at an angle ⁇ of about 10-20° (e.g., about 15°).
  • an additional taper located at an outlet end of lid 158 may increase the overall internal taper angle to about 30°.
  • a reinforcement anchor (shown in Figs. 33 and 34) 195 may be connected to an outside of base 152 near outlet end 156 to capture a loose end of the reinforcement during storage (e.g., the loose end may be wrapped around anchor 165).
  • Base 152 may be configured to internally receive any number of nozzles 168 and/or teasing mechanisms 169 between inlet end 154 and outlet end 156.
  • four nozzles 168A, 168B, 168C and 168D are disposed in series along a trajectory of the reinforcement passing through module 52. It is contemplated, however, that a different number (e.g., a greater number or a lesser number) of nozzles 168 may be utilized, as desired.
  • nozzles 168 may function to limit an amount of matrix passing through module 52 with the reinforcement and/or to shape the reinforcement. In most instances, at least one entry nozzle 168A and at least one exit nozzle 168D should be employed to reduce undesired passage of matrix out of module 52 in upstream and downstream directions, respectively.
  • Nozzles 168 may divide the enclosure of module 52 into one or more chambers or sections.
  • nozzles 168 divide the enclosure into a main wetting chamber 170 located between nozzles 168B and 168C, an upstream overflow chamber 172 located between nozzles 168 A and 168B, and a downstream overflow chamber 174 located between nozzles 168C and 168D.
  • chamber 170 may be a primary location at which the reinforcement is intended to be wetted with matrix. While the reinforcement may additionally be wetted within each of the overflow chambers 172 and 174, these overflow chambers 172 and 174 may primarily be intended as locations where excess resin can be collected and/or removed from module 52. The collection and removal of excess resin from overflow chambers 172 and 174 may help to inhibit undesired leakage from module 52 at ends 154 and 156.
  • Nozzles 168 may have different sizes and/or configurations.
  • nozzles 168A, 168B, and 168C may be slightly larger (e.g., have larger internal diameters) than nozzle 168D, in some applications. This may help to reduce friction acting on the reinforcement while the reinforcement is being pulled through main wetting chamber 170, yet still ensure precise control over a matrix-to-fiber ratio in the material discharging from module 52.
  • the nozzle(s) 168 located upstream of mechanism 169 may have a shape that substantially matches an as-fabricated shape of the reinforcement (e.g., rectangular), while the nozzles 168 located downstream of mechanism 169 may have a different shape (e.g., circular or elliptical) designed to achieve a desired characteristic (enhanced steering and/or placement accuracy) within structure 12.
  • a desired characteristic enhanced steering and/or placement accuracy
  • circular or elliptical nozzles 168 may also be simpler and/or less expensive to manufacture with high tolerances.
  • Teasing mechanism(s) 169 may be located inside main wetting chamber 170. Teasing mechanisms 169 may facilitate the intrusion (e.g., coating, saturation, wetting, etc.) of matrix throughout the reinforcement. In one example, this may be achieved by providing one or more pressure surfaces over which the reinforcements pass during transition through chamber 170. The pressure surfaces may press the matrix transversely through the reinforcements. In another example, the intrusion of matrix may be facilitated by the spreading out and/or flattening of individual fibers that make up the reinforcement (e.g., without generating a significant pressure differential through the reinforcement). In the disclosed example, multiple pressure surfaces cooperate to perform at least some (e.g., all) of these functions at the same time.
  • mechanism 169 includes three rollers that are spaced apart from each other in the direction of reinforcement travel. With this configuration, the rollers may altematingly press against opposing sides of the reinforcement.
  • the rollers spaced furthest apart from each other may have axes that lie within a common horizontal (i.e., horizontal with respect to the perspective of Fig. 20) plane.
  • the middle roller may have an axis that is parallel with the plane, but offset in a normal direction by a distance Y.
  • the rollers may together cause the reinforcement R to deviate from a straight-line path through module 52, and the distance Y may correspond with an angle or amount of the deviation.
  • a greater distance Y may result in a greater pressure differential generated by each roller and/or a greater amount of spreading/flattening/intrusion.
  • a greater distance Y may also relate to a greater frictional or drag force acting on the reinforcement,
  • the distance Y may be about 0-15mm (e.g., about 0-5mm) and result in a corresponding interior angle of the reinforcement at the middle roller of about 60-150° (e.g., about 110° to 145°).
  • variability may be built into the middle roller of mechanism 169.
  • a frame 173 having multiple axial positions 175 may be available for use with the middle roller, each position providing a different associated Y distance.
  • the frame and middle roller may be replaced as a single unit with another frame and middle roller having a different range, number, and/or granularity of positions.
  • the middle roller being mounted within a frame that can be selectively removed from inside of chamber 170, facilitates threading of the reinforcement through module 52.
  • One or more of the rollers e.g., the middle roller
  • the offset distance Y may be related to parameters of the reinforcement, the matrix intended to be effectively used inside module 52, and/or a sizing applied to the reinforcement by the reinforcement manufacturer.
  • brittle fibers may need more gentle redirecting achieved by either making the roller diameter larger and/or making the offset distance Y smaller.
  • fibers with larger filaments e.g., fiberglass has larger filaments than carbon fiber; T1100 carbon fiber has smaller filaments than AS4 carbon fiber; etc.
  • fibers with larger filaments e.g., fiberglass has larger filaments than carbon fiber; T1100 carbon fiber has smaller filaments than AS4 carbon fiber; etc.
  • smaller tows e.g., 3k, 300 Tex
  • larger tows e.g., 12k, 1200 Tex
  • Lower viscosity resins are also easier to impregnate with.
  • the offset distance Y may grow as a cross- sectional area of the reinforcement and/or a viscosity of the matrix increases. The growing distance Y may result in a higher-pressure differential through the reinforcement that drives migration of the matrix.
  • matrix may be pumped by module 46 into chamber 170 of module 52 via inlet port 212.
  • module 46 may be selectively activated to pump matrix into chamber 170 based on a detected pressure inside chamber 170. For example, when a pressure within chamber 170 drops below a low threshold pressure (e.g., about .25-.3S psi or about .29 psi), controller 20 may generate a signal activating pumping of module 46. Likewise, when a high threshold pressure (e.g., about .85-.9 psi or about .87 psi) is reached within chamber 170, controller 20 may stop sending the signal to module 46.
  • Pressure sensor 214 may be in communication with the matrix inside chamber 170 via port 208 and be used to generate the above-described pressure signals.
  • Some of the matrix pumped into chamber 170 may leak both upstream into chamber 172 (e.g., through and/or around nozzle 168B) and downstream into chamber 174 (e.g., through and/or around nozzle 168C).
  • gravity may force matrix from chamber 170 into chamber 172 or 174. This excess matrix, if unaccounted for, may continue to leak in the same manner upstream and/or downstream through or around nozzles 168 A and/or 168D and be lost into the environment.
  • the excess matrix may be drained from chambers 172 and 174 via outlet ports 210.
  • a low-pressure source 224 may connect with ports 210 to remove the excess matrix collected within chambers 172 and 174.
  • the removed excess resin may be recirculated back into module 52 via the primary inlet port 212 or additional dedicated inlet ports 212A (shown in Fig. 21). In other embodiments, the removed excess resin may be discarded.
  • a temperature of module 52 may be regulated for enhanced wetting and/or curing control.
  • a heater e.g., a ceramic heating cartridge - see Fig. 18
  • a temperature sensor e.g., a Resistance Temperature Detector - RTD
  • heater 182 is located upstream of sensor 184, such that the matrix is heated before passing by sensor 184.
  • the matrix may be heated to about 20-60°C (e.g., 40-50°C), depending on the application, the reinforcement being used, the matrix being used, and desired curing conditions.
  • a higher viscosity resin, a larger tow, and/or an opaquer reinforcement may require higher temperatures within module 52.
  • the materials of module 52 may be selected to provide desired performance characteristics.
  • base 152 and/or lid 158 may be fabricated from aluminum to provide a lightweight, easily machinable and low-cost component.
  • the aluminum may be coated with a non-stick and/or inert layer that protects against degradation by the matrix. This may include, for example a coating of Polytetrafluoroethylene (PTFE), parylene, or another polymer.
  • Nozzles 168 may be fabricated from a high-hardness material for longevity in a highly abrasive environment. This material may include, for example, stainless steel (e.g., 303, 304 or 440c). In some applications, the stainless steel may need to be passivated to eliminate contact and reaction between iron within the stainless steel and the matrix.
  • nozzles 168 may be fabricated from a ceramic material, if desired.
  • Components of mechanism 169 may be fabricated from PTFE to provide low friction characteristics, and be kept as small as possible to reduce mass and inertia.
  • Seal 161 and/or 206 may be fabricated from a closed-cell foam, such as a synthetic rubber and fluoropolymer elastomer commercially known as Viton, Tygon, silicon, or a PTFE foam.
  • Figs. 22, 23, and 24 illustrate an exemplary nozzle 168A and/or 168B. Although these nozzles are shown as being utilized twice within module 52, starting at inlet end 154, it is contemplated that these nozzle designs may be utilized a different number of times and/or in other locations, if desired.
  • nozzle 168A/B may generally embody a 2- piece rectangular unit, including a base 186 and a lid 188 that together define a channel 190 through which the reinforcement passes.
  • one or more magnets 200 may be embedded into one or both of base 186 and lid 188 to connect these components together in a removable manner.
  • Fig. 22 illustrate an exemplary nozzle 168A and/or 168B. Although these nozzles are shown as being utilized twice within module 52, starting at inlet end 154, it is contemplated that these nozzle designs may be utilized a different number of times and/or in other locations, if desired.
  • nozzle 168A/B may generally embody a 2- piece rectangular unit, including
  • one or more fasteners may be located at transverse sides of channel 190 to connect lid 188 to base 186.
  • the rectangular unit may be removably fitted into corresponding rectangular slots formed in base 152 of module 52 (see Fig. 19), and oriented transversely to the travel direction of the reinforcement through module 52.
  • each nozzle 168A/B may be completely recessed within base 152 (See Fig. 20).
  • nozzle 168 could alternatively be partially recessed within each of base 152 and lid 158, if desired (although this may increase a machining cost and complexity of module 52).
  • Base 186 of nozzle 168A/B may be configured to internally receive lid 188.
  • base 186 may form a three-sided enclosure, including an elongated spine, an entrance side 196 connected to a long edge of spine, and an exit side 198 connected to another long edge of spine opposite entrance side 196.
  • Entrance and exit sides 196, 198 may extend a distance past an inner surface of spine to form a slot therebetween that is oriented orthogonally to an axis of the reinforcement passing through the nozzle 168A/B.
  • Lid 188 when assembled to base 186, may fit completely into the slot, such that outer surfaces of lid 188 are generally flush with ends of entrance and exit sides 196, 198.
  • the inner surface of spine may be recessed or stepped down away from lid 188 at a lengthwise center thereof to form three connected sides (e.g., a bottom side and connected transverse sides) of channel 190.
  • An inner surface of lid 188 may be generally planar and form a fourth side (e.g., an upper side) of channel 190.
  • a depth of channel 190 may be defined solely by the step formed within spine (e.g., a height dimension of the lateral sides), thereby allowing for easy machinability of channel 190 via conventional processes and high tolerances.
  • the tolerances of channel 190 may be about +/- 0.00025", allowing for variance in a fiber-to-matrix ratio to be limited at about 2.5%.
  • Outer edges of channel 190 may be rounded to reduce damage to the reinforcement passing therethrough.
  • the rectangular shape of channel 190 may provide for optimum use of a similarly shaped reinforcement. That is, a reinforcement having an as-manufactured rectangular cross-section may pass through the rectangular shape of channel 190 without significant distortion. This may allow the reinforcement to pass over the pressure surfaces of mechanism 169 and be wetted in an efficient manner without causing damage to the reinforcements.
  • the reinforcements may be laid down against an underlying surface in a smooth or flat manner that reduces voids or undesired (e.g., uneven or bumpy) contours.
  • channel 190 within at least nozzle 168D may have a circular or ellipsoidal shape that facilitates smoother curving trajectories.
  • channel 190 may have only a curving shape (e.g., an incomplete arc of a circle) rather than a complete circle or ellipsoid, if desired.
  • Figs. 25, 26, 27, and 28 illustrate exemplary nozzles 168C and 168D each as having a generally circular cross-sectional bore.
  • the location of these nozzles downstream of mechanism 169 may allow for enhanced wetting while the reinforcement remains in it’s as- manufactured shape and enhanced steering during discharging via molding of the reinforcement into a curving shape.
  • nozzles 168C/D may each be unibody components having a similar rectangular base 203 that fits inside of wetting module base 152 and a similar internal bore (e.g., tapered and circular orifice).
  • Nozzle 168D may have an elongated and tapering tip end 207, in which an internal shape 205 is formed.
  • tip end 207 may help to enhance the formfactor of module 52.
  • a larger internal bore 209 may pass through base 203 and communicate with the internal shape 205, without increasing backpressure or friction. It is contemplated that nozzles 168C and 168D could be identical, if desired.
  • At least nozzle 168D has a cross-sectional area selected to limit an amount of matrix clinging to the reinforcement being discharged from module 52.
  • the cross-sectional area of nozzle 168D may be 0-150% greater (e.g., 65-150% greater) than the cross-sectional area of the reinforcement alone.
  • upstream nozzles 168A-C may have the same cross-sectional area as nozzle 168D to simplify and lower a cost of module 52.
  • the upstream nozzles 168A-C could have different (e.g., larger) cross-sectional areas, if desired (e.g., to facilitate threading and/or reduce drag).
  • all nozzles 168 may have identical cross-sectional areas, as drag at these ratios may be insignificant.
  • one or more upstream nozzles 168 e.g., nozzles 168A, B, and/or C
  • one or more downstream nozzles e.g., nozzles 168C and/or D
  • the upstream nozzles 168 could have tighter geometry to inhibit undesired leakage of resin at the upstream locations.
  • Figs. 29, 30, 31 and 32 illustrate alternative exemplary nozzles 168A-D that are similar to the embodiments of Figs. 25-28.
  • nozzles 168A-D of Figs. 29- 32 may externally be generally cuboid and have cylindrical internal passages.
  • nozzles 168A-D of Figs. 29-32 may additionally include a seal 330 that wraps at least partially around base 203.
  • seal 330 wraps around three sides of base 203 (e.g., around a bottom side, and opposing lateral sides).
  • an upper side of base 203 located opposite the bottom side and extending between the opposing lateral sides may be sealed via seal 161 associated with lid 158(referring to Fig. 19).
  • Seal 330 may be applied to base 203 via overmolding, adhesive-backing, or another technique and inhibit matrix leaking through around the sides of each nozzle 168.
  • FIG. 33, 34 and 35 An alternative wetting module 52 is illustrated in Figs. 33, 34 and 35. As can be seen in these images, this module 52 may include base 152, lid 158, seal 161, nozzles 168, teasing mechanism 169, heater 182 and sensor 184. However, the arrangement and/or configurations of these elements may be different than in the previously disclosed embodiments. For example, while heater 182 and sensor 184 may still be in communication with main chamber 170 (e.g., with heater 182 being located further upstream than sensor 184), heater 182 may approach chamber 170 through a bottom side of base 152 (e.g., from a side opposite lid 158) and sensor 184 may be mounted to an external surface of base 152 at the bottom side. This rearrangement may provide increased heating efficiency, particularly in situations where a lesser amount of matrix is present within chamber 170. In addition, at this orientation, there may be a lower risk of associated wiring becoming bent and/or broken.
  • the module 52 embodiment of Figs. 33-35 also has new geometry that facilitates a startup and/or purge process.
  • a bleed port 300 (shown in Fig. 33) may be formed in communication with main chamber 170. Bleed port 300 may be normally closed off, for example via a plug 302.
  • wetting module 52 may be bled of air trapped therein by removing plug 302 or otherwise opening bleed port 300 and pumping pressurized matrix into main chamber 170. This may continue for a set period of time, until air no longer is pushed through bleed port 300, and/or until matrix discharges through bleed port 300.
  • a drain channel 304 may be formed within an outer side surface of base 152 and configured to direct any matrix purged through bleed port 300 to a drip location away from discharge end 156.
  • drain channel 304 starts at bleed port 300 near an open top side of base 152, and extends forward (e.g., closer towards discharge end 156) and toward the back side of base 152.
  • a disposable reservoir (not shown) may be placed at an exit end of channel 304 during the startup/purging operation to collect any purging matrix.
  • nozzles 168 have also been modified for the wetting module embodiment of Figs. 33 and 34.
  • nozzles 168 in this embodiment may have a rounded exterior shape (i.e., cylindrical rather than cuboid). This may allow for a random placement and orientation within base 152 of module 52 (e.g., during first assembly and subsequent maintenance activities) that provides for an extended useful life of these components.
  • each of nozzles 168 may include a seal (e.g., an o-ring) 306 retained within an annular groove 308 located at an upstream end and configured for an interference fit within a corresponding bore (not shown) in base 152.
  • each of nozzles 168 may include a central passage 310 that tapers outward at both entrant and exit ends 312, 314.
  • an angle of tapers at ends 312, 314 may be about 30-60° relative to an axis of the central passage.
  • Nozzle 168 may have an additional taper 316 located closer to the exit taper than the entrant taper.
  • An angle of taper 316 may be less than about 45° (e.g., about 30°).
  • the entrant taper may facilitate threading of the reinforcement through nozzle 168.
  • an entrant diameter-to-exit diameter ratio may be limited to a maximum of 3.5 or threading can become too difficult (e.g., by causing buckling).
  • a passage depth-to-diameter (not including entrant/exit taper diameters) ratio may be about 7 to 15, as anything outside this range may make fabriction too difficult and/or expensive.
  • the exit taper may inhibit fraying of the reinforcement.
  • Taper 316 may allow for a reduced cross-sectional area that sets a predefined ratio of reinforcement to matrix.
  • Interchangeable nozzles 168D may be available with differently sized cross-sectional areas downstream of taper 316 to provide different ratios.
  • Each of nozzles 168 shown in Figs. 36 and 37 may include a placement shoulder 318 configured to facilitate accurate placement of the corresponding nozzle 168 into base 152 (referring to nozzles 168A,B,C) and/or accurate placement of nozzle 168D relative to module 58. While shoulders 318 may inhibit insertion past a desired position, care should still be taken to ensure that nozzles 168 are inserted far enough (e.g., up to engagement with base 152) and remain fully seated during operation. For this purpose, one or more positioning/retaining devices 320 may be included within module 52.
  • each device 320 is provided separately for each nozzle 168 and protrudes from an inner surface of lid 158 (e.g., through an opening in seal 161).
  • each device 320 may be generally forked, having an open center to allow passage of the reinforcement extending through the corresponding nozzle 168.
  • the tines (curved or straight tines) located at each side of the open center may be configured to engage an end surface of shoulder 318 opposite base 152 to ensure an adequate insertion depth.
  • the tines taper, such that the corresponding nozzle 168 is urged further into the bore of base 152 as lid 158 is pivoted to a greater degree of closure.
  • the taper may be about 90-135°. A taper outside this range may not allow for smooth closure of lid 158.
  • module 56 may be an assembly of components that cooperate to sever the reinforcement passing from module 52 to module 58.
  • These components may include, among other things, a mounting bracket 280 connected to actuator 272, a cutting mechanism (e.g., a rotary blade) 282, a cutting actuator (e.g., a rotary motor) 284 connecting mechanism 282 to bracket 280 via associated hardware (e.g., bearings, washers, fasteners, shims, gears, belts, etc.) 286, and a cover 288 configured to at least partially enclose (e.g., enclose on at least two or at least three sides) cutting mechanism 282.
  • a mounting bracket 280 connected to actuator 272
  • a cutting mechanism e.g., a rotary blade
  • a cutting actuator e.g., a rotary motor
  • cover 288 configured to at least partially enclose (e.g., enclose on at least two or at least three sides) cutting mechanism 282.
  • an extension of actuator 272 may cause cutting mechanism 282 to protrude into a trajectory of the reinforcement approaching module 58.
  • Activation of actuator 284 may cause mechanism 282 to rotate such that, during the protruding, mechanism 282 may sever the reinforcement.
  • Cover 288 may protect against unintentional contact with a cutting edge of mechanism 282 and also function to collect dust and debris cast radially outward from mechanism 282 during severing. It is contemplated that actuator 284 may be configured to affect a different severing motion (e.g., a vibration, a side-to-side translation, etc.) of mechanism 282, if desired.
  • a different severing motion e.g., a vibration, a side-to-side translation, etc.
  • engagement of the rotating cutting mechanism with the reinforcement can cause the reinforcement to deviate from a desired location relative to module
  • transverse motion of the reinforcement may be selectively inhibited during severing. This may be accomplished, for example, via a guide 290.
  • Guide 290 may be an assembly of components that cooperate to selectively inhibit undesired motion (e.g., transverse motion relative to a trajectory past cutting mechanism 282) of the reinforcement during severing. These components may include, among other things, one or more (e.g., a pair of) arms 292 and an extension 294 that extends from a carriage 301 (discussed below in regard to Fig. 68) to arm(s) 292.
  • undesired motion e.g., transverse motion relative to a trajectory past cutting mechanism 282
  • These components may include, among other things, one or more (e.g., a pair of) arms 292 and an extension 294 that extends from a carriage 301 (discussed below in regard to Fig. 68) to arm(s) 292.
  • each of arm(s) 292 may include a distal end 292a configured to abut the reinforcement at one side (e.g., relative to the trajectory of the reinforcement), and a proximal end 292b configured to operatively engage a corresponding feature (e.g., a pocket or recess) of extension 294.
  • Each of arm(s) 292 may be pivotally connected to actuator 284, for example via a bearing 296. This connection may allow free pivoting of arm(s) 292 about bearing 296 and simultaneous translation together with actuator 284 and mechanism 282 that is unaffected by rotations thereof.
  • each of arm(s) 292 is generally L-shaped, having a first and longer segment extending from bearing 296 to distal end 292a, and a second and shorter segment extending from bearing 296 to proximal end 292b at an angle of about 60-120° (e.g., about 90°) relative to the first segment.
  • a portion of proximal end 292b e.g., a pin, a stud, a boss, etc.
  • extension 294 translation of actuator 284 and mechanism 282 relative to extension 294 (e.g., via extension of actuator 272) may cause pivoting of arm(s) 292 between an open position (shown in Fig. 39) and a closed position (shown in Fig. 40) via the linkage of proximal end(s) 292b with the pockets of extension 294.
  • arms 292 When arms 292 are in the closed position, a spacing therebetween and a corresponding distance that the reinforcement is allowed to deviate from a nominal position may be smallest.
  • the spacing may be related to a cross-sectional area of the reinforcement (e.g., the ration of areagap may be about 0.5 or greater for proper severing of the reinforcement).
  • a single arm 292 placed to oppose motion of the reinforcement caused by engagement with the rotating edge of mechanism 282 may be sufficient in some applications.
  • paired arms 292 may allow for mechanism 282 to be rotated in any direction and still provide sufficient resistance to reinforcement motion.
  • actuator 284 may be controlled to switch rotation directions for every other severing event, thereby extending a lifespan of mechanism 282 (e.g., by using twice as much cutting edge at each vertex of mechanism 282).
  • module 58 is illustrated in Figs. 41, 42 and 43. As shown in these figures, module 58 may be broken down into multiple (e.g., two, three, or more) subassemblies. These subassemblies may include one or more of a leading (i.e., leading relative to a traveling direction of head 16 during normal material discharge and fabrication of structure 12) subassembly 218, a trailing subassembly 221, and a curing subassembly 222.
  • leading subassembly 218, a trailing subassembly 221, and a curing subassembly 222 may be broken down into multiple (e.g., two, three, or more) subassemblies. These subassemblies may include one or more of a leading (i.e., leading relative to a traveling direction of head 16 during normal material discharge and fabrication of structure 12) subassembly 218, a trailing subassembly 221, and a
  • each of these subassemblies may be connected to each other to form module 58 and move together to wipe over (e.g., smooth, distribute matrix, etc.), compact, and/or cure the material discharging from module 52.
  • subassembly 221 may be rigidly mounted to a leading side of subassembly 222 via one or more fasteners (not shown), and subassembly 218 may be pivotally mounted to a leading side of subassembly 221 (e.g., opposite subassembly 222) via one or more (e.g., two) pins 226.
  • a spring 228 may extend between subassemblies 218 and 221 to bias subassembly 218 against the discharging material (e.g., downward away from head 16 - see Fig. 42). As module 58 is moved towards the material, subassembly 218 may be the first to engage the material. Further movement may cause subassembly 218 to pivot upwards against the bias of spring 228 and away from the material, until subassembly 221 also engages the material (see Fig. 43).
  • Subassembly 218 may be the first subassembly of module 58 to engage and condition the material discharging from module 52, relative to the normal travel direction of head 16.
  • subassembly 218 may include, among other things, pivoting end brackets 230 that mount to pins 226 of subassembly 221 (see Fig. 42) via respective bearings 232, a conditioner 234, and one or more (e.g., two) springs 228.
  • Conditioner 234 may extend laterally across leading ends of brackets 230 and be held in place by one or more fasteners 236.
  • Springs 228 may engage trailing ends of brackets 230 to bias the pivoting of conditioner 234 toward the discharging material.
  • Bearings 232 may mount inside corresponding bores 238 located midway between the leading and trailing ends of brackets 230.
  • conditioner 234 is a blade-like wiper fabricated from a compressible and/or low-friction material (e.g., PTFE).
  • conditioner 234 is a cylindrical rolling or non-rolling wiper. It is contemplated that both a roller and a wiper could be utilized together within subassembly 218 (e.g., in series), if desired.
  • Conditioner 234 in addition to providing a first level of compaction and/or matrix smoothing function, may also shield the matrix from cure energy transmitted by downstream components that will be discussed in more detail below.
  • Subassembly 221 may include components that cooperate to further compact and/or wipe over the discharging material, In some applications, subassembly 221 may additionally trigger at least some curing of the matrix. In one embodiment, subassembly 221 provides about 4-5 times more compaction than subassembly 218. For example, subassembly 218 may provide about 0.75-1. ON (e.g., 0.9N) of compaction, while subassembly 221 may provide about 4.0-5. ON (e.g., 4.4N) of compaction. As shown in Figs.
  • the components of subassembly 221 include, among others, a pair of oppositely arranged roller mounts 242, a roller 244 mounted to each of inwardly extending stub shafts 245 of mounts 242 via a pair of corresponding bearings 246, a cover 248 received over an annular surface of roller 244, and one or more (e.g., two) energy transmitters 250 that extend between one or more (e.g., the same or different) distal sources (e.g., simultaneously or independently activated light sources) and roller 244.
  • roller 244 is larger (e.g., has a greater diameter and/or contact surface area) than the roller/wiper of conditioner 234, although that may not always be the case (e.g., the sizes may be the same or reversed).
  • Roller mounts 242 may be mirrored opposites of each other, each having an outer bracket end for mounting subassembly 221 to subassembly 222, and stub shaft 245 extending inwardly from the bracket end. Bearings 246 may be pressed onto stub shafts 245. Pins 226 may be generally coaxial with stub shafts 245 and protrude axially outward from the bracket end of roller mounts 242. A passage or recess may be formed within each of roller mounts 242 to receive a corresponding transmitter 250. The passage may extend at an oblique angle ⁇ (shown in Fig. 45) from the outer bracket end of mount 242, axially inward and toward the material being passed over by roller 244.
  • ⁇ shown in Fig. 45
  • the angle ⁇ of each passage and transmitters 250 may be about 30-90° (e.g., 30-65°).
  • the angle ⁇ may help to focus the energy from transmitters 250 axially inward toward a general center of roller 244 and to an upper exposed surface of the material being passed over by roller 244.
  • the angle ⁇ may also help cure an exposed side edge of the material.
  • the passages and transmitters 250 may additionally or alternatively be tilted forward at an oblique angle ⁇ (see Figs. 42 and 43), such that the energy from transmitters 250 is directed toward subassembly 222 and away from subassembly 218.
  • the angle ⁇ of the passages and transmitters 250 is about 165-180°.
  • the angle 8 may help to focus the energy from transmitters 250 at or downstream of a nip point of roller 244 to avoid premature curing at a location not yet passed over by conditioner 234 and/or roller 244.
  • Roller 244 may have unique geometry that facilitates simultaneous compaction and curing of the material being passed over by subassembly 221. As shown in Figs. 45 and 46, roller 244 may be generally cylindrical, having a center bore 254 formed therein to receive bearings 246 (referring to Fig. 46). Center bore 254, at each axial end of roller 244, may taper radially inward at an angle ⁇ toward an outer edge of bearings 246. In one embodiment, angle ⁇ is about 30-40° (e.g., 35°) and oriented generally orthogonal to the axes of transmitters 250 at outlets of transmitters 250 (referring to Fig. 45).
  • One or more energy channels 256 may extend from the tapered inner surfaces of center bore 254 radially outward through an outer annular surface of roller 244 and axially inward toward an axial center of roller 244. Channels 256 may generally be aligned or parallel with the axis of passages 252 and transmitters 250 at the outlets of transmitters 250, such that energy may flow from transmitters 250 through channels 256 with little, if any, obstruction.
  • channels 256 are about 1.0-1.5mm in diameter (e.g., 1.125mm) and spaced about 1.25-1.75mm (e.g., 1.5mm) axis-to-axis.
  • Three channels 256 are formed at each radial spoke of the tapered regions, with the axial locations being staggered between adjacent radial spokes to allow tighter nesting between adjacent channels 256.
  • roller 244 could have a simpler form, in some applications.
  • roller 244 could be a simple cylinder fabricated from an energy -transparent material (see Fig. 43).
  • roller 244 may be utilized without transmitters 250 directing cure energy therethrough (see Figs. 47-54), if desired.
  • Cover 248 may be press fit over roller 244 and perform multiple functions.
  • cover 248 provides a generally solid surface over the open ends of channels 256. This may reduce a likelihood of the material picking up a pattern from roller 244 and inhibit ingress of the material (e.g., of the matrix).
  • cover 248 may provide a low-friction surface that reduces a likelihood of the matrix sticking to subassembly 221.
  • cover 248 may help to diffuse or distribute some of the energy exiting channels 256 at a surface of the material being compacted and cured.
  • cover 248 may be an inexpensive and easily replaced wear component that limits wear of the more permanent and expensive roller 244.
  • Subassembly 222 may include components that cooperate to further cure the discharging material.
  • subassembly 222 is configured to through-cure or complete curing of the matrix that was only triggered by subassembly 221.
  • subassembly 222 may include, among other things, a bracket 260 to which one or more energy transmitters 250 are connected.
  • two energy transmitters 250 are shown as arranged in mirrored opposition to each other (similar to the arrangement shown in Fig. 41 for subassembly 221).
  • Energy transmitters 250 in subassembly 222 may be the same identical transmitters used in subassembly 221 or different, as desired.
  • the outlets of transmitters 250 in subassembly 222 may be tilted inward relative to a symmetry plane that passes through the reinforcement R. It is also contemplated that the tips of transmitters 250 may additionally or alternatively be tilted in the fore-aft direction, if desired. Tilting of transmitters 250 toward subassembly 221 may allow for curing closer to the nip point of roller 244, which may increase an accuracy in reinforcement placement.
  • Bracket 260 may be generally U-shaped. Legs of the U-shape may be used to mount module 58 to the rest of head 16. An empty space between the legs of the U-shape may provide clearance for module 56 (see Figs. 68-70).
  • subassemblies 218-222 may be mounted to move together (e.g., relative to a remainder of head 16), as a single unit. It is contemplated, however, that one or both of subassemblies 218, 221 could alternatively or additionally move relative to subassembly 222.
  • both of assemblies 218 and 221 may be slidingly connected to bracket 260 (e.g., via a guide and rail mechanism 262) and configured to move in a direction generally orthogonal to an underlying print surface and/or the normal travel direction of print head 16 during material discharge.
  • a resilient member (e.g., a spring) 264 may bias subassemblies 218 and 221 away from the rest of print head 16 (e.g., downward, toward the underlying print surface).
  • Transmitters 250, of the embodiment of Fig. 47, may all trail behind (i.e., not pass through or lead) assemblies 218 and 221.
  • Conditioner 234, in this embodiment, may be a foam cylinder or block that does not rotate.
  • a mount 266 may be provided to removably receive the foam cylinder and allow for quick (e.g., snap-out/snap-in) replacement after a period of wear.
  • a stomper 268 may be provided within module 58, in some embodiments, for temporary use in anchoring a tag-end of a new path of material discharging from head 16.
  • Stomper 268 may be generally transparent to the energy from transmitters 250 and configured to press downward on the tag-end of a reinforcement at print-start of the new path.
  • stomper 268 may be fabricated from an acrylic material and mounted rigidly to bracket 260. Assemblies 218 and 221 may be urged by spring 264 to normally extend downward past stomper 268 and be forced upward by engagement with an underlying surface to allow stomper 268 to press against the discharging material (e.g., via further downward motion of head 16 and bracket 260).
  • bracket 260 may be retracted until stomper 268 no longer contacts the material. Only subassemblies 218 and 221 may continue to contact the material at this time, for normal (e.g., non-startup) payout of the material (see Fig. 48).
  • One or more (e.g., one pair of) transmitters 250 may direct cure energy through stomper 268 from opposing sides, while one or more (e.g., one pair of) transmitters 250 may expose the material to additional cure energy at a location downstream of both stomper 268 and subassembly 218. It should be notated that energy may not be directed through roller 244 in this embodiment. It is contemplated that stomper 268 may be omitted from the configuration of Fig. 48, if desired.
  • Module 58 of Figs. 49 and 50 may be similar to module 58 of Figs. 47 and 48.
  • assemblies 218 and 221 may be substantially identical, and a stomper 270 may be included that functions similar to stamper 268.
  • cure energy may be directed through stamper 270 (e.g., only during anchoring or continuously during discharging) and only downstream of (i.e., not through) roller 244 of subassembly 218.
  • subassembly 218 may be rigidly mounted to bracket 260.
  • stamper 270 and subassembly 221 may together be moveably (e.g., pivotally) connected to bracket 260 independent of subassembly 218, and biased (e.g., by spring 264) to extend downward past subassembly 218 and first engage the discharging material as bracket 260 is extended (see Fig. 50).
  • further extension of bracket 260 may cause upwards pivoting of stamper 270 and subassembly 218 against the spring bias and away from the material until both of subassembly 218 and subassembly 221 (e.g., with or without stamper 270) are exerting pressure against the material (see Fig. 49).
  • Fig. 51 illustrates an example of module 58 that is similar to module 58 of Figs. 49 and 50, in that subassembly 221 and stamper 270 pivot together around subassembly 218.
  • an orientation of spring 264 is different in the embodiment of Fig. 51 (e.g., extending from another component of head 16 at a leading side, instead of to bracket 260, and rotated about 270° relative to the embodiment of Figs. 49 and 50).
  • Figs. 52, 53 and 54 illustrate modifications of module 58, compared to what is shown in Fig. 51.
  • stamper 270 may be omitted and multiple stages of curing (e.g., two pairs of transmitters 250 in series) may be located downstream of both of assemblies 218 and 221.
  • subassembly 218 includes roller 244.
  • roller 244 is replaced by a sliding device (e.g., a wiper) 500 that includes a centering or guiding slot 505 to receive the reinforcement from module 52.
  • a sliding device e.g., a wiper
  • Transmitters 250 may be paired in spaced apart (i.e., leading/trailing) stages and extend from the same or different sources to provide the same or different intensities and/or types of cure energy. It is contemplated that only a single stage of transmitters 250 could alternatively be utilized, if desired.
  • Fig. 55 illustrates yet another example of module 58.
  • roller 244 shown in Fig. 55 may be cylindrical and configured passes cure energy (e.g., via a transparent annular surface) to the underlying material.
  • the cure energy is directed radially from outside of roller 244 completely through the transparent annular surface of roller 244.
  • Additional transmitters 250 may be located at a trailing side of subassembly 218 to further curing of the material, as desired.
  • No stampers or wipers are included in the depicted embodiment, although such devices shown in the other examples could be added to the embodiment of Fig. 55 at locations upstream and/or downstream of roller 244, if desired.
  • module 58 A final embodiment of module 58 is illustrated in Figs. 56, 57 and 58. As shown in these figures, module 58 of this embodiment may be similar to the embodiment of Figs. 52-54. For example, module 58 may still be broken down into multiple (e.g., two, three, or more) subassemblies, including a trailing or curing subassembly 222 and one or more leading or conditioning subassembly 218, 221 that leads curing subassembly 222.
  • multiple subassemblies including a trailing or curing subassembly 222 and one or more leading or conditioning subassembly 218, 221 that leads curing subassembly 222.
  • Each of these subassemblies may be connected to bracket 260 (e.g., via one or more locating pins and/or other fasteners) to form module 58 and move together to wipe over (e.g., smooth, distribute matrix, etc.), compact, and/or cure the material discharging from module 52.
  • bracket 260 e.g., via one or more locating pins and/or other fasteners
  • wipe over e.g., smooth, distribute matrix, etc.
  • curing assembly 222 may include, among other things, an adapter 324 configured to hold at least two (e.g., two pairs of) of oppositely arranged energy transmitters 250.
  • transmitters 250 are light pipes that extend from one or more remote cure sources (e.g., light sources such as lasers, UV lights, etc. - not shown) to locations near the composite material being compacted by subassembly 222.
  • Transmitters 250 may be held within corresponding bores 331 of adapter 324 via resilient members (e.g., o-rings) 332 that contract during installation and expand into corresponding annular channels within bores 331 upon full insertion.
  • Adapter 324 may be generally C-shaped (e.g., when viewed from above in the perspective of Fig. 57), having a spine and legs that extend in the same direction from opposing ends of the spine. Bores 331 may be formed within the legs of the C-shape and inclined toward a center plane of symmetry passing through module 58 (i.e., such that tip our outlet ends of transmitters 250 extending through bores 331 are closer to the discharging material than bores 331). The angle of this incline may be substantially similar to the angle ⁇ shown in Fig. 45, such that an internal angle between transmitters 250 may be about 50-120°.
  • transmitters 250 may be tilted in a direction of print head travel, similar to what is shown in Fig. 42. However, in contrast to the embodiment of Fig. 42, transmitters 250 may be tilted such that their outlet ends are closer to conditioner 234. For example, transmitters may be tilted relative to a normal of the surface being compacted by an angle 8 that is about 90-135°. In some embodiments, the trailing set of transmitters 250 may be tilted by a greater angle, such that the corresponding areas of exposure on the compacted material overlap by a greater amount.
  • the embodiment of Figs. 56-58 includes a pair of transmitters 250 mounted within each leg of the C-shape.
  • the leading transmitter 250 of the pair may extend a greater distance in a z-direction toward the discharging material compared to the trailing transmitter 250 (see Fig. 58). This may allow for a greater intensity of cure from the leading transmitter 250 and a greater area of cure from the trailing transmitter 250.
  • the staggard mounting distance of transmitters 250 may also enhance clearance at the discharge end of head 16, allowing for fabrication within tighter constraints.
  • mounting of transmitters 250 (and/or other components) at the discharge end of head 16 may be affected by the matrix being discharged and/or curing of that matrix. For example, mounting using fasteners can be problematic when the matrix coats the fasteners and is cured. For this reason, transmitters 250 may be mounted in a fastener-less manner.
  • a compacting roller 244 and a sliding or wiping conditioner 234 may be rotationally and/or pivotally mounted within a common frame (e.g., a 2- piece frame) 340 via one or more bearings 342 and a shaft 344 passing through bearings 342 into frame 340.
  • conditioner 234 trails roller 244 relative to a normal travel direction of head 16. It should be noted, however, that this relationship could be reversed, if desired.
  • Conditioner 234 may be mounted to pivot about roller 244 and biased (e.g., via a spring 346) toward the material being discharged from head 16.
  • roller 244 may be fabricated from a relatively harder and stiffer material than an outer surface of conditioner 234, allowing for roller 244 to provide a primary or greater compacting force than conditioner 234 and for conditioner 234 to deform somewhat and provide a primary wiping-of- matrix function. It should be noted, however, that conditioner 234 may still provide some compaction to the material passing thereby, and that roller 244 may still provide some smoothing of the matrix, if desired. Conditioner 234, in addition to providing the matrix smoothing function and/or some compaction, may also shield the matrix from cure energy passing from trailing transmitters 250 to the material being compacted/smoothed.
  • roller 244 may have a larger diameter cross-section than wiper 234 (e.g., 0-5 times as large) to allow for the desired functionality without sacrificing form factor.
  • Axial lengths should be nearly identical for each of roller 244 and wiper 234 (e.g., 1.5-3 times an applied with of the reinforcement). It should be noted that a smaller diameter roller 244 may allow for higher resolution in printing, while a larger diameter conditioner 234 may provide a greater compliance and therefor better wiping.
  • the axial lengths of these components may allow for a desired pressure and resolution, without risking that the reinforcement will walk off the ends of these components.
  • conditioner 234 may be configured for simple and quick replacement after a period of wear.
  • conditioner 234 may include a dovetail projection 700 configured to be received within a corresponding recess of a pivot arm 702.
  • Spring 346 may connect to an end of arm 702 opposite conditioner 234.
  • Fig. 64 illustrates a virtual model of structure 12 to be fabricated by system 10 (e.g., a model created by a user of system 10 via a conventional CAD system).
  • the model along with known characteristics (e.g., a size and shape) of the material M to be used in the fabrication, may be used to generate one or more target paths in which the material should be deposited to create structure 12.
  • the fabricated structure 12 substantially matches the virtual model.
  • a centerline or center axis of the deposited material is intended to lie in the target path at all locations along the target path.
  • the material discharging from module 52 has a generally rectangular shape, with a width dimension in a Y- dir ection, a thickness dimension in a Z-direction, and a length dimension in an X-direction.
  • the width of the material may be greater than the thickness.
  • the length may vary between paths and be dictated by the model and controlled by selectively severing the material at different locations.
  • the centerline may be defined by intersection of y-z and x-z planes at each point along the path.
  • head 16 should be moved and steered about a tool center point (TCP) that is coincident with the centerline or center axis of the material.
  • TCP tool center point
  • the TCP may be located differently, depending on the configuration of module 58.
  • Fig. 65 illustrates the location of the TCP to be used with the module-58 configuration having a leading device (LD) that first moves (e.g., rolls) over and compacts the material discharging from module 52, followed by a trailing device (TD) that moves (e.g., slides) over and wipes the material. It should be noted that some wiping may be caused by the LD and some compacting may be caused by the TD, if desired. Neither the LD or the TD include an integral transmitter 250 in this embodiment. That is, only transmitters) 250 that trail behind the TD are included.
  • LD leading device
  • TD trailing device
  • the TCP is located between an LDx (e.g., an x-coordinate of the LD axis) and a TDx (e.g., a leading edge of a wiper zone associated with the TD in the x- direction), and closer to the LDx than the TDx.
  • the TCP may not be within a pressure zone of the LD (e.g., a zone in which the LD is exerting a compacting pressure through the material) or within a wipe zone of the TD.
  • the TCP is located within a Y-Z plane encompassing a discharge nozzle axis 272 of module 52 and is orthogonal to an underlying surface at the TCP.
  • the TCP is located a 1 ⁇ 2-thickness of the material (e.g., after compression by the LD) below a Y-X plane encompassing the wipe surface of the TD and a tangent of the LD.
  • a Y-axis of the LD is maintained parallel to the underlying surface at the TCP and an upper or lower surface of the rectangular shape of the material.
  • a final rotational axis of support 14, commonly known as a J6-axis may be maintained normal to the underlying surface at the TCP and the upper or lower surface of the rectangular shape of the material.
  • Axis 272 may be angled away from the J6-axis by about 30- 60° (e.g., about 45°).
  • Fig. 66 illustrates the location of the TCP to be used with the module-58 configuration having only a leading device (LD) that moves (e.g., rolls) over and compacts the material discharging from module 52 (i.e., a configuration without a trailing device that moves over and compacts/wipes the material). It should be noted that some or only wiping (e.g., with some or no compacting) may be caused by the LD, if desired.
  • the LD may include one or more integral transmitters) 250, additional trailing transmitters) 250, only trailing transmitters) 250, or no transmitters at all.
  • the TCP is located within the compression/wipe zone of the LD (e.g., at a point in the x-direction of highest pressure - the nip point). In some embodiments, the TCP may be located a distance (e.g., 1-10 times a thicknesses of the material) forward of the nip point, but still within the compression/wipe zone. As with all embodiments, the TCP is located within the Y-Z plane encompassing the discharge nozzle axis of module 52, and located a 1 ⁇ 2-thickness of the material (e.g., after compression by LD) below the Y-X plane encompassing the tangent of the LD that is parallel with the underlying surface.
  • a Y-axis of the LD is maintained parallel to an underlying surface at the TCP and an upper or lower surface of the rectangular shape of the discharging material.
  • the J6-axis may be maintained normal to underlying surface at the TCP and the upper or lower surface of the rectangular shape.
  • Axis 272 may be angled away from the J6-axis by about 30-60° (e.g., about 45°).
  • Fig. 67 illustrates the location of the TCP to be used with the module-58 configuration having a leading device (LD) that first moves (e.g., wipes) over the material discharging from module 52, followed by a trailing device (TD) that moves (e.g., rolls) over and compacts the material.
  • LD leading device
  • TD trailing device
  • the TD may include an integral transmitter 250 in this embodiment.
  • the TCP is located between an LDx (e.g., a trailing edge of the wipe surface) and a TDx (e.g., a leading edge of the pressure zone), and closer to the LDx than the TDx.
  • the TCP may not be within the wipe zone of the LD or the pressure zone of the TD.
  • the TCP is located within a Y-Z plane encompassing a discharge nozzle axis 272 of module 52 and is orthogonal to an underlying surface at the TCP.
  • the TCP is located a 1 ⁇ 2-thickness of the material (e.g., after compression by TD) below a Y-X plane encompassing the wipe surface of the LD and a tangent of the TD.
  • a Y-axis of the TD is maintained parallel to the underlying surface at the TCP and an upper or lower surface of the rectangular shape of the discharging material.
  • a final rotational axis of support 14, commonly known as a J6-axis may be maintained normal to the underlying surface at the TCP and the upper or lower surface of the rectangular shape.
  • Axis 272 may be angled away from the J6-axis by about 30-60° (e.g., about 45°).
  • a position of module 58 relative to print head 16 and/or a pressure applied by module 58 to the discharging material may be selectively adjusted in a local manner.
  • module 58 (together with module 56, in some embodiments), may be movingly connected to lower plate 26 via a carriage 301 and a rail 303.
  • Carriage 301 may be rigidly connected to bracket 260, while rail 303 may be rigidly connected to lower plate 26.
  • Carriage 301 may be configured to slide or roll along rail 303 in a direction generally parallel to the J6 axis and orthogonal to a surface of structure 12 at the TCP.
  • One or more actuators may be controlled to selectively cause carriage 301 (along with module 58) to slide relative to rail 303.
  • a first actuator 305 may exert an upward force
  • a second actuator 306 exerts a downward force.
  • carriage 301 may move upwards, and vice versa.
  • the upward force is maintained constant and only the downward force is varied to achieve upward or downward motion and a corresponding pressure exerted by module 58 on the material.
  • a sensor 309 may be detect a position of module 58 relative to the rest of head 16 and generate a corresponding signal used to responsively regulate operation of actuators) 304, 306.
  • a range of travel of module 58 may include the range of travel of carriage 301 along rail 303 and a range of travel of subassembly 218 relative to bracket 260 (see Figs. 47 and 48).
  • bracket 260 being connected to carriage 301, may travel a first distance that is equal to a length of rail 303 and/or a travel distance of actuator 306, and subassembly 218 may travel a second distance associated with rail and guide mechanism 262. In one embodiment, the second distance may be about 1 ⁇ 2 to 1 ⁇ 4 of the first distance.
  • subassembly 218 may normally be biased along mechanism 262 toward a fully extended position by spring 264.
  • carriage 301 may be extended until subassembly 218 engages the discharging material and is pushed back upward against the bias of spring 264 to a location about midway between the fully extended and fully retracted positions. Carriage 301 may then be locked at this extension position, and head 16 may thereafter be moved along predefined tool paths to discharge material. Subassembly 218 may be allowed to extend or retract away from the midway-location via mechanism 262 with or against the bias of spring 264 during material discharge, as necessary to accommodate an uneven underlying surface and/or provide a relatively consistent amount of pressure against the material.
  • subassembly 218 may be implemented as often as desired.
  • subassembly 218 may be reset to the midway location of carriage 301 at start of each new path, at start of each new layer, partway through a path, partway through a layer, on a periodic basis, after a minimum length of material has been discharged, etc.
  • Locker 400 may include at least an actuator 402 that is affixed to plate 26 and configured to operatively engage a moveable portion of carriage 301 and/or module 58 to lock carriage 301 to plate 26.
  • an extension 404 is also included that extends from carriage 301 to actuator 402 (e.g., through plate 26). Extension 404 is rigidly connected to carriage 301, and actuator 402 may be selectively activated to halt movement of carriage 301 via engagement with extension 404.
  • extension 404 is shown as a plate that extends through a corresponding slot in plate 26, other configurations (e.g., rods, tracks, chains, etc.) may also be possible. Further, although actuator 402 is illustrated as a pneumatic clamp that sandwiches extension 404 between opposing friction members, other configurations are also possible.
  • carriage 301 may be locked at only select times. For example, carriage 301 may be locked during a fiber-severing event, during discharge of material around a curving trajectory, during transition from supported printing to free-space printing, during printing of only specific layers within structure 12, and/or during printing of only accuracy-critical areas of structure 12.
  • Locking carriage 301 (and in turn the vertical motion of module 58) during a severing event may help to reduce reactionary motion of module 58 caused by activation of module 56. That is, because of the connected relationship between modules 56 and 58, when module 56 is activated to move downward toward the material (e.g., by actuator 272 - see Fig. 69), a reverse or upwards force may be reactively generated within module 58, causing module 58 to lift away from the material. The opposite may also be true. Locking of carriage 301 to the rest of print head 16 via locker 400 may reduce these reactionary responses.
  • Locking carriage 301 (and in turn the motion of module 58) during discharge along a curving trajectory may help to reduce a buildup of material at comers within structure 12. That is, during such discharging, the material tends to roll and/or fold upon itself due to its rectangular cross-section. If unaccounted for, this could undesirably increase a thickness of the material at the comers.
  • module 58 may exert a greater pressure on the material at the comers (by resisting being pushed away from the thicker material), thereby helping to squish the material to a desired thickness.
  • Locking carriage 301 (and in turn the motion of module 58) during transition from supported printing to free-space printing may reduce discontinuities at the transition location. That is, if module 58 were free to move at the transition location, module 58 would immediately be spring-biased to extend to its fullest extent after moving off a supported surface due to the sudden lack of reactionary forces. By locking module 58 at the transition location, module 58 should remain at a relatively constant extended position, even though the reactionary forces may still fall away when moving from supported to unsupported printing.
  • Locking carriage 301 (and in turn the motion of module 58) at specified layers and/or critical features of structure 12, accuracy in the shape and/or size of structure 12 may be improved. That is, not all layers of structure 12 need to be accurately placed, and a thickness of these layers may be allowed to grow uncontrollably to some extent. However, to help ensure that an overall shape and/or size of structure 12 matches a desired profile (e.g., at a mating interface), carriage 301 may be locked during fabrication of particular layers and/or features to force those layers and/or features to conform to design limitations. Locking may be performed periodically (e.g., ever other layer, every 5 th layer, every 10 th layer, etc.) and/or at strategic locations of critical dimensions.
  • Figs. 72, 73 and 74 illustrate a method of fabricating structure 12 utilizing any of the disclosed embodiments. Figs. 72-74 will be discussed in more detail below to further illustrate the disclosed concepts.
  • the disclosed system and print head may be used to manufacture composite structures having any desired cross-sectional size, 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, each coated with a common matrix. Operation of system 10 will now be described in detail with reference to Figs. 1-74.
  • information regarding a desired structure 12 may be loaded into system 10 (e.g., into controller 20 that is responsible for regulating operations of support 14 and/or head 16).
  • This information may include, among other things, a size (e.g., diameter, wall thickness, length, etc.), a shape, a contour (e.g., a trajectory), surface features (e.g., ridge size, location, thickness, length; flange size, location, thickness, length; etc.) and finishes, connection geometry (e.g., locations and sizes of couplers, tees, splices, etc.), locationspecific matrix stipulations, location-specific reinforcement stipulations, compaction requirements, curing requirements, pressure settings, viscosities, flowrates, etc. It should be noted that this information may alternatively or additionally be loaded into system 10 at different times and/or continuously during the manufacturing event, if desired.
  • one or more different reinforcements and/or matrixes may be selectively loaded into head 16.
  • one or more supplies of reinforcement may be loaded onto creel 19 (referring to Figs. 1-5) of module 44, and one or more cartridges 110 of matrix may be placed into vessel 112 of module 46 (referring to Fig. 9).
  • the reinforcements may then be threaded through head 16 prior to start of the manufacturing event. Threading may include passing the reinforcement from module 44 around portions of module 48 and through module 50. The reinforcement may then be threaded through module 52 and wetted with matrix. Module 52 may then move to an extended position to place the wetted reinforcement under module 58. Module 58 may thereafter be extended to press the wetted reinforcement against an underlying layer. After threading is complete, head 16 may be ready to discharge matrix-coated reinforcements.
  • one or more cure sources of module 58 may be activated, module 50 may be deactivated to release the reinforcement, and head 16 may be moved away from a point of anchor to cause the reinforcement to be pulled out of head 16 and at least partially cured. This discharge may continue until discharge is complete and/or until head 16 must move to another location of discharge without discharging material during the move.
  • module 58 may move (e.g., roll and/or wipe) over the reinforcements.
  • a pressure may be applied against the reinforcements by module 58, thereby compacting the material.
  • the cure source(s) of module 58 may remain active during material discharge from head 16 and during compacting, such that at least a portion of the material is cured and hardened enough to remain tacked to the underlying layer and/or to maintain its discharged shape and location.
  • a majority (e.g., all) of the matrix may be cured by exposure to energy from module 58.
  • the component information may be used to control operation of system 10.
  • the reinforcements may be discharged from head 16 (along with the matrix), while support 14 selectively moves head 16 in a desired manner during curing, such that an axis of the discharging material follows a desired trajectory (e.g., a free-space, unsupported, 3-D trajectory) and forms structure 12.
  • module 46 may be carefully regulated by controller 20 such that the reinforcement is wetted with a precise and desired amount of the matrix.
  • modules 44 and 48 may together function to maintain a desired level of tension within the reinforcement.
  • the level of tension could be variable, in some applications.
  • the tension level could be lower during anchoring and/or shortly thereafter to inhibit pulling of the reinforcement during a time when adhesion may be lower.
  • the tension level could be reduced in preparation for severing and/or during a time between material discharge. Higher levels of tension may be desirable during free-space printing to increase stability in the discharged material. Other reasons for varying the tension levels may also be possible.
  • Figs. 72 and 73 illustrate a method of fabricating structure 12.
  • structure 12 may be fabricated from a plurality of layers 600 (e.g., 600a, 600b, 600c and 600d) that are discharged adjacent each other (e.g., on top of each other) in an overlapping manner.
  • layers 600 e.g., 600a, 600b, 600c and 600d
  • the outermost paths of each layer 600 would terminate at an exact boundary edge 605.
  • the boundary edge 605 is generally staggard somewhat and results in a rough outer surface.
  • the transversely outermost paths may intentionally be cantilevered by a desired amount at every other layer.
  • the non-cantilevered paths extend to a first location and the cantilevered paths are initially placed to extend past the first location (e.g., partway or all the way to edge 605).
  • the cantilevered paths are pressed downward and curve inward to a final resting position at an intended location (e.g., at boundary edge 605).
  • the cantilevering may be accomplished by staggering the paths of a first layer relative to the paths of an adjacent layer by an amount less than a width of each path (e.g., by about 1 ⁇ 4 to 1 ⁇ 2 of the width). This staggering may be accomplished throughout an entire crosssection of every other layer or only within paths (e.g., 1-10 paths) that lie near the boundary edge.
  • system 10 may rely on the materials (e.g., the reinforcement and the matrix) being used within system 10 having established quality parameters.
  • the matrix should have an expected viscosity and formula.
  • viscous oligomers and/or solid particles may settle out of the matrix or agglomerate. This may cause the viscosity and/or formula of the matrix to deviate from expected values. Unless otherwise accounted for, these changes could cause system 10 to malfunction and/or for structure 12 to have properties below expected values.
  • One way to help ensure the materials being used within system 10 have quality parameters within acceptable limits may be to compare operations of modules 46 and 52 with expected operations once system 10 has been loaded with a particular cartridge 110 of matrix.
  • matrix may be supplied from module 46 to module 52 in an amount and/or at a rate the provides a desired operating pressure within module 52 for a given temperature of the matrix. That is, as a pressure measured by sensor 214 (referring to Figs. 13 and 21) within module 52 falls below a low limit, additional matrix is pumped (or pumped at a higher rate) from module 46 into module 52. Likewise, as the pressure measured by sensor 214 rises above a high limit, less matrix is pumped (or pumped at a lower rate) from module 46 into module 52.
  • a regulated air pressure within module 46 should produce an expected and corresponding pressure within module 52 for the given temperature of the matrix. As the quality parameters of the matrix deviate from acceptable values, the relationship between regulated air pressure in module 46 and resulting matrix pressure within module 52 may likewise deviate.
  • controller 20 may have stored in memory one or more maps that relate the regulated air pressure to an expected matrix pressure for a given matrix parameter (e.g., viscosity, age, formula, temperature, etc.).
  • the map may be in the form of an equation, a table, a graph, etc.
  • An exemplary map 800 that can be used for this purpose is shown in Fig. 74.
  • Map 800 may be a graph having a first (e.g., x) axis that represents a temperature of the matrix inside of module 52, and a second (e.g., y) axis that represents pressure (e.g., the actual air pressure in module 48 - curve 805, an expected air pressure in module 48 - curve 810, and/or the sensed matrix pressure in module 52 - curve 815).
  • One or more thresholds e.g., a high-threshold 820 and a low- threshold 825) may bound curve 810.
  • high- and low-thresholds 820, 825 may be offset from curve 810 by equal amounts. In another embodiment, however, high- threshold 820 may be offset by an amount greater than low-threshold 825.
  • Controller 20 may selectively reference a temperature of the matrix (e.g., as measured via sensor 184) and the actual air pressure required with module 48 to produce the regulated matrix pressure within module 52 with thresholds 820 and 825. As long as the actual air pressure within module 48 falls between thresholds 820 and 825 for the given temperature, controller 20 may conclude that the matrix has the required quality parameters. Otherwise, controller 20 may determine that the matrix should not be used and selectively trigger a responsive action (e.g., cause system 10 to shut down and/or to generate an alert).
  • a responsive action e.g., cause system 10 to shut down and/or to generate an alert.
  • controller 20 may, in some embodiments, only make the above-described comparison during particular operations (e.g., during cutting) when material is not being discharged or discharged at a rate known to provide a stable pressure relationship.
  • controller 20 may, in some embodiments, only make the above-described comparison during particular operations (e.g., during cutting) when material is not being discharged or discharged at a rate known to provide a stable pressure relationship.
  • the above-described comparison between pressures of modules 48 and 52 could additionally or alternatively be used to detect and/or diagnose system failures that are not related to materials.
  • a rate of deviation between expected and actual pressures could be used to diagnose clogging and/or pinching of a conduit extending between modules 48 and 52, binding or another mechanical failure of module 48, etc.

Abstract

Est divulgué, un système (10) destiné à la fabrication additive d'un objet (12). Ce système peut comprendre un support (14) et une tête d'impression (16) reliée fonctionnellement au support et mobile par l'intermédiaire de ce dernier. La tête d'impression peut comprendre une sortie (52) conçue pour évacuer un matériau, un dispositif d'attaque (244) et un dispositif arrière (234) relié de façon pivotante au dispositif d'attaque. Le dispositif d'attaque peut être conçu pour venir en prise et se déplacer sur le matériau après l'évacuation. Le dispositif arrière peut être conçu pour venir en prise avec le matériau et se déplacer sur ce dernier au niveau d'un emplacement à l'arrière du dispositif d'attaque.
PCT/US2022/075958 2021-09-04 2022-09-03 Tête d'impression pour système de fabrication additive WO2023035004A1 (fr)

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Application Number Priority Date Filing Date Title
US202163260919P 2021-09-04 2021-09-04
US63/260,919 2021-09-04
US202163265827P 2021-12-21 2021-12-21
US63/265,827 2021-12-21
US202263268044P 2022-02-15 2022-02-15
US63/268,044 2022-02-15
US17/929,659 US20230071473A1 (en) 2021-09-04 2022-09-02 Print head and method for additive manufacturing system
US17/929,662 US20230073782A1 (en) 2021-09-04 2022-09-02 Print head and method for additive manufacturing system
US17/929,665 US20230073014A1 (en) 2021-09-04 2022-09-02 Print head and method for additive manufacturing system
US17/929,666 2022-09-02
US17/929,666 US20230070818A1 (en) 2021-09-04 2022-09-02 Print head and method for additive manufacturing system
US17/929,663 2022-09-02
US17/929,659 2022-09-02
US17/929,663 US20230071513A1 (en) 2021-09-04 2022-09-02 Print head and method for additive manufacturing system
US17/929,665 2022-09-02
US17/929,662 2022-09-02

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9511543B2 (en) 2012-08-29 2016-12-06 Cc3D Llc Method and apparatus for continuous composite three-dimensional printing
EP3124212A2 (fr) * 2015-07-31 2017-02-01 The Boeing Company Système de fabrication de parties composites de manière additive
US20200023172A1 (en) * 2018-07-19 2020-01-23 Sunnybrook Research Institute Devices and methods for wound-conformal guidance of bioprinter printhead
US20210260821A1 (en) 2020-02-25 2021-08-26 Continuous Composites Inc. Additive manufacturing system

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9511543B2 (en) 2012-08-29 2016-12-06 Cc3D Llc Method and apparatus for continuous composite three-dimensional printing
EP3124212A2 (fr) * 2015-07-31 2017-02-01 The Boeing Company Système de fabrication de parties composites de manière additive
US20200023172A1 (en) * 2018-07-19 2020-01-23 Sunnybrook Research Institute Devices and methods for wound-conformal guidance of bioprinter printhead
US20210260821A1 (en) 2020-02-25 2021-08-26 Continuous Composites Inc. Additive manufacturing system

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