Continuous Composites Inc.

United States of America

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IPC Class
B29C 64/209 - Heads; Nozzles 146
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor 141
B33Y 10/00 - Processes of additive manufacturing 130
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes 96
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM] 90
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1.

PRINT HEAD AND METHOD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 18506779
Status Pending
Filing Date 2023-11-10
First Publication Date 2024-05-16
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Overby, Andrew John
  • Wilson, Stephen Tyler
  • Jones, Christopher Lee
  • Milbourne, Michael John

Abstract

A system is disclosed 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 first module configured to discharge a material, a second module configured to compact the material, and an actuator connected to the second module and configured to apply a force to the second module. The system may further include a controller in communication with the actuator. The controller may be configured to determine an operating parameter of the print head, and to selectively adjust the force applied by the actuator to the second module based on the operating parameter.

IPC Classes  ?

  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

2.

METHOD AND APPARATUS FOR CONTINUOUS COMPOSITE THREE-DIMENSIONAL PRINTING

      
Application Number 18500029
Status Pending
Filing Date 2023-11-01
First Publication Date 2024-02-29
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing

3.

METHOD AND APPARATUS FOR CONTINUOUS COMPOSITE THREE-DIMENSIONAL PRINTING

      
Application Number 18500039
Status Pending
Filing Date 2023-11-01
First Publication Date 2024-02-29
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing

4.

METHOD AND APPARATUS FOR CONTINUOUS COMPOSITE THREE-DIMENSIONAL PRINTING

      
Application Number 18500400
Status Pending
Filing Date 2023-11-02
First Publication Date 2024-02-29
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing

5.

ADDITIVE MANUFACTURING SYSTEM

      
Application Number 18319013
Status Pending
Filing Date 2023-05-17
First Publication Date 2024-02-08
Owner Continuous Composites Inc. (USA)
Inventor
  • Kliphardt, Wesley John
  • Wilsey, Brennon Scott
  • Jones, Christopher Lee

Abstract

A system is disclosed for additively manufacturing a structure. The system may have a pedestal, a motion platform mounted to the pedestal, and a print head coupled to the motion platform. The system may also include an enclosure at least partially surrounding the motion platform and the print head, and a print surface configured to selectively dock with the pedestal.

IPC Classes  ?

  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/245 - Platforms or substrates
  • B29C 64/209 - Heads; Nozzles
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

6.

Additive Manufacturing System

      
Application Number 18312234
Status Pending
Filing Date 2023-05-04
First Publication Date 2023-11-16
Owner Continuous Composites Inc. (USA)
Inventor
  • Wilson, Stephen Tyler
  • Brendel, John Paul
  • Stockett, Ryan C.
  • Stranberg, Nathan Andrew
  • Overby, Andrew John
  • Armstrong, Sam
  • Johnson, Maxwell Joseph
  • Wilsey, Brennon Scott
  • Howard, Matt

Abstract

A system is disclosed for additively manufacturing a structure. The system may have a support, and a print head operatively connected to and moveable by the support. The print head may include a first module configured to discharge a material, a second module configured to compact the material as it discharges from the first module, and a controller in communication with the second module. The controller may be configured to determine an as-discharged characteristic of the material, and to selectively adjust a force of the second module based on the as-discharged characteristic.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/218 - Rollers
  • B29C 64/209 - Heads; Nozzles

7.

PRINT HEAD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 18170140
Status Pending
Filing Date 2023-02-16
First Publication Date 2023-06-22
Owner Continuous Composites, Inc. (USA)
Inventor
  • Budge, Trevor David
  • Jahner, Brock Adam
  • Smith, Jeremiah R.
  • Stranberg, Nathan Andrew
  • Stulc, Andrew Michael
  • Vandenberg, Samuel
  • Wilson, Stephen Tyler
  • Overby, Andrew John

Abstract

A system is disclosed for additively manufacturing a composite structure. 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 in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/343 - Metering
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/314 - Preparation
  • B29C 64/295 - Heating elements
  • B33Y 40/10 - Pre-treatment

8.

SYSTEMS AND METHODS FOR CONTROLLING ADDITIVE MANUFACTURING

      
Application Number 18153168
Status Pending
Filing Date 2023-01-11
First Publication Date 2023-05-25
Owner Continuous Composites Inc. (USA)
Inventor
  • Stockett, Ryan C.
  • Tyler, Kenneth L.
  • Alfson, Blake L.
  • Coad, Josiah D.

Abstract

A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to determine a plurality of tension vectors to be generated within the structure, and to generate a plan for manufacturing the structure. The plan may include tool paths that arrange continuous fibers within the structure to generate the plurality of tension vectors. The processor may also be configured to execute the computer-executable instructions to cause the additive manufacturing machine to follow the plan and manufacture the structure.

IPC Classes  ?

  • G05B 19/042 - Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles

9.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 18156368
Grant Number 11964426
Status In Force
Filing Date 2023-01-18
First Publication Date 2023-05-18
Grant Date 2024-04-23
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing

10.

SYSTEMS AND METHODS OF ADDITIVE MANUFACTURING

      
Application Number 18047496
Status Pending
Filing Date 2022-10-18
First Publication Date 2023-04-20
Owner CONTINUOUS COMPOSITES INC. (USA)
Inventor
  • Johnson, Maxwell Joseph
  • Stranberg, Nathan Andrew
  • Stockett, Ryan C.
  • Negugogor, Mikel
  • Bosman, Chase
  • Lalonde, Logan
  • Wilson, Stephen Tyler
  • Losee, Christopher

Abstract

A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths within a first layer. Each of the first plurality of paths may have a center portion, a first portion extending away from the center portion to at least partially form a first branch, and a second portion integral extending away from the center portion opposite the first portion to at least partially form a second branch. The method may further include depositing a second plurality of paths primarily within the first layer. Each of the second plurality of paths may have a center portion, and a first portion extending away from the center portion to at least partially form a third branch of the joint. The second plurality of paths may cross over and be bonded to the first plurality of paths to form spaced-apart bumps that extend into a second layer.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing

11.

SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING

      
Application Number 18047528
Status Pending
Filing Date 2022-10-18
First Publication Date 2023-04-20
Owner Continuous Composites Inc. (USA)
Inventor
  • Johnson, Maxwell Joseph
  • Stranberg, Nathan Andrew
  • Stockett, Ryan C.
  • Negugogor, Mikel
  • Bosman, Chase
  • Lalonde, Logan
  • Wilson, Stephen Tyler
  • Losee, Christopher

Abstract

A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths to form a base layer of a joint in the structure. The method may also include depositing a second plurality of paths that pass through the joint. At least one of the second plurality of paths may extend away from the base layer through free space.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing

12.

SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING

      
Application Number 18047490
Status Pending
Filing Date 2022-10-18
First Publication Date 2023-04-20
Owner Continuous Composites Inc. (USA)
Inventor
  • Johnson, Maxwell Joseph
  • Stanberg, Nathan Andrew
  • Stockett, Ryan C.
  • Negugopor, Mikel
  • Bosman, Chase
  • Lalonde, Logan
  • Wilson, Stephen Tyler
  • Losee, Christopher

Abstract

A method is disclosed for additively manufacturing of a joint within a structure using a composite material. The method may include depositing a first path of the composite material within a first layer at the joint. The first path may have a center portion at a center of the joint, and a first portion integral with the center portion and extending away from the center portion. The first portion may form at least part of a first branch having a first density. The center of the joint may have a second density. The first density may be greater than the second density.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

13.

SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING

      
Application Number 18047492
Status Pending
Filing Date 2022-10-18
First Publication Date 2023-04-20
Owner Continuous Composites Inc. (USA)
Inventor
  • Johnson, Maxwell Joseph
  • Stranberg, Nathan Andrew
  • Stockett, Ryan C.
  • Negugogor, Mikel
  • Bosman, Chase
  • Lalonde, Logan
  • Wilson, Stephen Tyler
  • Losee, Christopher

Abstract

A method is disclosed for manufacturing a joint. The method may include depositing a first path of composite material within a first layer at the joint. The first path may have a center at a center of the joint, a first portion integral with the center portion and extending away from the center portion, and a second portion integral with the center and extending away from the center portion. The method may further include depositing a second path of composite material within the first layer at the joint. The second path may have a center at the center of the joint, and a first portion integral with the center of the second path and extending away from the center of the second path. The center portion of the second path may be parallel with, abut and be bonded to the center portion of the first path.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing

14.

SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING

      
Application Number 18047527
Status Pending
Filing Date 2022-10-18
First Publication Date 2023-04-20
Owner Continuous Composites Inc. (USA)
Inventor
  • Johnson, Maxwell Joseph
  • Stranberg, Nathan Andrew
  • Stockett, Ryan C.
  • Negugogor, Mikel
  • Bosman, Chase
  • Lalonde, Logan
  • Wilson, Stephen Tyler
  • Losee, Christopher

Abstract

A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths within a first layer of the structure that passes through the joint in a first configuration. The method may further include applying a transformation to the first configuration to form a second configuration. The method may additionally include depositing a second plurality of paths within a second layer of the structure to at least partially overlap the first plurality of paths and pass through the joint in the second configuration.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

15.

PRINT HEAD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 18059842
Status Pending
Filing Date 2022-11-29
First Publication Date 2023-04-20
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Jahner, Brock Adam
  • Smith, Jeremiah R.
  • Stranberg, Nathan Andrew
  • Stulc, Andrew Michael
  • Vandenberg, Samuel
  • Wilson, Stephen Tyler
  • Overby, Andrew John

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/295 - Heating elements
  • B29C 64/314 - Preparation
  • B29C 64/343 - Metering
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 40/10 - Pre-treatment
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material

16.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 18065568
Grant Number 11926094
Status In Force
Filing Date 2022-12-13
First Publication Date 2023-04-13
Grant Date 2024-03-12
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing

17.

METHOD AND APPARATUS FOR CONTINUOUS COMPOSITE THREE-DIMENSIONAL PRINTING

      
Application Number 18065595
Status Pending
Filing Date 2022-12-13
First Publication Date 2023-04-13
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns

18.

PRINT HEAD AND METHOD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17929659
Status Pending
Filing Date 2022-09-02
First Publication Date 2023-03-09
Owner Continuous Composites Inc. (USA)
Inventor
  • Overby, Andrew John
  • Stranberg, Nathan Andrew
  • Wilson, Stephen Tyler
  • Armstrong, Sam
  • Johnson, Maxwell Joseph
  • Vandenberg, Samuel

Abstract

A method is disclosed 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.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/336 - Feeding of two or more materials
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

19.

PRINT HEAD AND METHOD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17929663
Status Pending
Filing Date 2022-09-02
First Publication Date 2023-03-09
Owner Continuous Composites Inc. (USA)
Inventor
  • Overby, Andrew John
  • Stranberg, Nathan Andrew
  • Wilson, Stephen Tyler
  • Armstrong, Sam
  • Johnson, Maxwell Joseph
  • Vandenberg, Samuel

Abstract

A system is disclosed 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.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

20.

PRINT HEAD AND METHOD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17929662
Status Pending
Filing Date 2022-09-02
First Publication Date 2023-03-09
Owner Continuous Composites Inc. (USA)
Inventor
  • Overby, Andrew John
  • Stranberg, Nathan Andrew
  • Wilson, Stephen Tyler
  • Armstrong, Sam
  • Johnson, Maxwell Joseph
  • Vandenberg, Samuel

Abstract

A system is disclosed 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.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber

21.

PRINT HEAD AND METHOD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17929665
Status Pending
Filing Date 2022-09-02
First Publication Date 2023-03-09
Owner Continuous Composites Inc. (USA)
Inventor
  • Overby, Andrew John
  • Stranberg, Nathan Andrew
  • Wilson, Stephen Tyler
  • Armstrong, Sam
  • Johnson, Maxwell Joseph
  • Vandenberg, Samuel

Abstract

A system is disclosed 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.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber

22.

SYSTEM FOR ADDITIVELY MANUFACTURING COMPOSITE STRUCTURE

      
Application Number 17935249
Status Pending
Filing Date 2022-09-26
First Publication Date 2023-01-12
Owner Continuous Composites Inc. (USA)
Inventor Stranberg, Nathan Andrew

Abstract

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and an outlet configured to discharge a material. The outlet may be operatively connected to and moveable by the support in a normal travel direction during material discharge. The outlet may include a guide, and a compactor operatively connected to the guide at a trailing location relative to the normal travel direction. The compactor may be moveable in an axial direction of the guide. The outlet may also include at least one cure enhancer mounted to move with the compactor relative to the guide. The at least one cure enhancer may be configured to expose the material to a cure energy.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/218 - Rollers
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/314 - Preparation
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B29C 64/227 - Driving means
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer

23.

ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17930620
Status Pending
Filing Date 2022-09-08
First Publication Date 2023-01-05
Owner Continuous Composites Inc. (USA)
Inventor Overby, Andrew John

Abstract

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head configured to discharge a material, a first structure, and a second structure. The first structure may be configured to move the print head within a plane during discharge of the material. The second structure may be configured to move the print head within the plane during material discharge, the second structure being movable together with the print head by the first structure.

IPC Classes  ?

  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/209 - Heads; Nozzles

24.

ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17659948
Status Pending
Filing Date 2022-04-20
First Publication Date 2022-12-29
Owner Continuous Composites Inc. (USA)
Inventor Stranberg, Nathan Andrew

Abstract

A method is disclosed for additively manufacturing a structure. The method may include discharging a composite material, including a reinforcement and a matrix, from a print head, and moving the print head during discharging to form the structure from the composite material. The method may further include exposing the composite material during discharging to a cure energy to trigger the matrix to harden, and selectively adding a filler to the composite material to cause the composite material to increase a temperature achieved when the composite material is exposed to the cure energy.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

25.

SYSTEMS AND METHODS FOR CONTROLLING ADDITIVE MANUFACTURING

      
Application Number 17652224
Status Pending
Filing Date 2022-02-23
First Publication Date 2022-12-01
Owner Continuous Composites Inc. (USA)
Inventor
  • Negugogor, Mikel
  • Lalonde, Logan
  • Morris, Rachael Kathleen

Abstract

Methods and associated systems and apparatus are disclosed for determining a tool path for use in additively manufacturing a structure. The methods may include receiving data that at least partially defines a plurality of intersecting elongate elements forming a layer of the structure, and determining, based on the received data, a graph structure comprising a plurality of edges each representing one of the plurality of intersecting elongate elements, and a node representing an intersection of at least two of the plurality of intersecting elongate elements. The method may also include determining a plurality of regions of the structure based on the graph structure, each region comprising one or more elongate elements, and generating a plurality of tool paths for each of the plurality of regions.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/209 - Heads; Nozzles

26.

System for additively manufacturing composite structure utilizing comparison of data cloud and virtual model of structure during discharging material

      
Application Number 17813835
Grant Number 11958238
Status In Force
Filing Date 2022-07-20
First Publication Date 2022-11-10
Grant Date 2024-04-16
Owner Continuous Composites Inc. (USA)
Inventor
  • Morris, Rachael Kathleen
  • Stockett, Ryan C.

Abstract

A system is disclosed for use in additively manufacturing a structure. The system may include a print head to discharge a material, and a support to move the print head during discharging to fabricate a structure. The system may also include a receiver mounted to the print head to generate a signal indicative of at least one of a shape, a size, and a location of the discharged material, and a processor in communication with the receiver and the support. The processor may be configured to generate a data cloud of the structure fabricated by the additive manufacturing system based on the signal and based on a known position of the receiver at a time of signal generation. The processor may also be configured to make a comparison of the data cloud and a virtual model of the structure during discharging, and to selectively affect discharging based on the comparison.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B29C 64/227 - Driving means
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/245 - Platforms or substrates
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/295 - Heating elements
  • B29C 64/314 - Preparation
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing

27.

ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17657995
Status Pending
Filing Date 2022-04-05
First Publication Date 2022-10-27
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Overby, Andrew John
  • Stulc, Andrew Michael
  • Wilson, Stephen Tyler
  • Stocket, Ryan C.
  • Jahner, Brock Adam

Abstract

A print head is disclosed for use in additively manufacturing an object. The print head may have a housing, and a wetting module configured to wet a reinforcement with a liquid matrix. The print head may also include a matrix supply configured to hold a quantity of the liquid matrix and supply the liquid matrix to the wetting module.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/295 - Heating elements

28.

Additive manufacturing system

      
Application Number 17657998
Grant Number 11958247
Status In Force
Filing Date 2022-04-05
First Publication Date 2022-10-27
Grant Date 2024-04-16
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Overby, Andrew John
  • Stulc, Andrew Michael
  • Wilson, Stephen Tyler
  • Stocket, Ryan C.
  • Jahner, Brock Adam

Abstract

A system is disclosed for use in additively manufacturing an object. The system may have a support and a first module operatively mounted to an end of the support and configured to discharge a material during motion of the support to form an object. The system may also have a second module configured to sever the material, at least a third module configured to at least one of compact or cure the material, and an actuator configured to cause movement of the second and the at least a third modules relative to the first module.

IPC Classes  ?

  • B29C 64/336 - Feeding of two or more materials
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/227 - Driving means
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B29C 64/357 - Recycling
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/10 - Pre-treatment
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

29.

Additive manufacturing system

      
Application Number 17651748
Grant Number 11926099
Status In Force
Filing Date 2022-02-18
First Publication Date 2022-10-27
Grant Date 2024-03-12
Owner Continuous Composites Inc. (USA)
Inventor
  • Stulc, Andrew Michael
  • Stranberg, Nathan Andrew

Abstract

A system is disclosed for additively manufacturing a structure. The system may include a motion platform, a print head, and a drive. The drive may include a base connectable to the motion platform, a slipring disposed inside of the base, and a drivetrain extending between the base and the print head.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B29C 64/336 - Feeding of two or more materials
  • B29C 64/357 - Recycling
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/227 - Driving means
  • B33Y 40/10 - Pre-treatment
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

30.

Additive manufacturing system

      
Application Number 17657994
Grant Number 11760021
Status In Force
Filing Date 2022-04-05
First Publication Date 2022-10-27
Grant Date 2023-09-19
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Overby, Andrew John
  • Stulc, Andrew Michael
  • Wilson, Stephen Tyler
  • Stocket, Ryan C.
  • Jahner, Brock Adam

Abstract

A system is disclosed for use in additively manufacturing an object. The system may have a reinforcement supply, a matrix supply, and a wetting module configured to separately receive reinforcement from the reinforcement supply and matrix from the matrix supply and to discharge the reinforcement wetted with the matrix. The wetting module may include a body forming an enclosure and having an inlet end configured to receive the reinforcement and an outlet end configured to discharge the reinforcement wetted with the matrix. The wetting module may also include a plurality of nozzles dividing the enclosure into at least a wetting chamber.

IPC Classes  ?

  • B29C 64/336 - Feeding of two or more materials
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/295 - Heating elements
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/357 - Recycling
  • B29C 64/245 - Platforms or substrates
  • B29C 64/241 - Driving means for rotary motion
  • B33Y 40/10 - Pre-treatment
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29C 64/227 - Driving means
  • B33Y 70/00 - Materials specially adapted for additive manufacturing

31.

ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17657997
Status Pending
Filing Date 2022-04-05
First Publication Date 2022-10-27
Owner Continous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Overby, Andrew John
  • Stulc, Andrew Michael
  • Wilson, Stephen Tyler
  • Stocket, Ryan C.
  • Jahner, Brock Adam
  • Losee, Christopher

Abstract

A method is disclosed for additively manufacturing an object. The method may include extending a first module of a print head to push a tag end of material adjacent a second module during a feeding routine. The method may also include extending the second module to push against the tag end, and activating a third module to at least partially cure the tag end and thereby adhere the tag end as an anchor.

IPC Classes  ?

  • B29C 64/336 - Feeding of two or more materials
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

32.

SYSTEMS AND METHODS FOR CONTROLLING ADDITIVE MANUFACTURING

      
Application Number 17808951
Status Pending
Filing Date 2022-06-24
First Publication Date 2022-10-06
Owner Continuous Composites Inc. (USA)
Inventor
  • Negugogor, Mikel
  • Lalonde, Logan
  • Morris, Rachael Kathieen

Abstract

Methods and associated apparatus for determining a 3-dimensional tool path for use in additively manufacturing a 3-dimensional layer of a structure. The method may include receiving 3-dimensional layer data defining at least part of the 3-dimensional layer of the structure. The method may include determining a mapping function. The method may include applying the mapping function to the 3-dimensional layer data to generate 2-dimensional layer data. The method may include generating a 2-dimensional tool path based on the 2-dimensional layer data. The method may include applying the mapping function to the 2-dimensional tool path to generate a 3-dimensional tool path.

IPC Classes  ?

  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing

33.

SYSTEMS AND METHODS FOR CONTROLLING ADDITIVE MANUFACTURING

      
Application Number 17652220
Status Pending
Filing Date 2022-02-23
First Publication Date 2022-08-25
Owner Continuous Composites Inc. (USA)
Inventor
  • Negugogor, Mikel
  • Lalonde, Logan
  • Morris, Rachael Kathleen

Abstract

Methods and associated systems and apparatus for determining a tool path for use in additively manufacturing a structure. The methods may include receiving data that at least partially defines an outer boundary for a region of the structure, partitioning the region based on placement of a partitioning line across the region from the outer boundary, and generating the tool path to navigate at least part of the outer boundary and to cross, at least partially, the region based on the placement of the partitioning line.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/245 - Platforms or substrates
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

34.

SYSTEMS AND METHODS FOR CONTROLLING ADDITIVE MANUFACTURING

      
Application Number 17652222
Status Pending
Filing Date 2022-02-23
First Publication Date 2022-08-25
Owner Continuous Composites Inc. (USA)
Inventor
  • Negugogor, Mikel
  • Lalonde, Logan
  • Morris, Rachael Kathleen

Abstract

Methods and associated systems and apparatus for determining a tool path for use in additively manufacturing a structure. The methods may include receiving placement data indicative of a relative placement of a plurality of nodes, each node including one or more regional tool paths and each regional tool path for additively manufacturing a region of the structure. The methods may also include receiving operation data indicative of an operation to be performed in relation to at least one of the plurality of nodes, and resolving the at least one of the plurality of nodes into a resolved tool path for use in additively manufacturing the structure based on the received placement data and operation data.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/245 - Platforms or substrates
  • B29C 64/209 - Heads; Nozzles
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

35.

ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17652223
Status Pending
Filing Date 2022-02-23
First Publication Date 2022-08-25
Owner Continuous Composites Inc. (USA)
Inventor
  • Negugogor, Mikel
  • Lalonde, Logan
  • Morris, Rachael Kathleen

Abstract

Methods and associated systems and apparatus are disclosed for determining a tool path for use in additively manufacturing a structure. The methods may include identifying a propagation surface onto which material forming at least part of the structure is to be deposited, and determining a structure boundary associated with the propagation surface and defining at least part of the structure. The methods may also include determining one or more structure layers offset from the propagation surface and laterally bounded by the structure boundary; generating a tool path for each structure layer.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/245 - Platforms or substrates
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

36.

SYSTEM FOR ADDITIVELY MANUFACTURING COMPOSITE STRUCTURES

      
Application Number 17659968
Status Pending
Filing Date 2022-04-20
First Publication Date 2022-08-04
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Stranberg, Nathan Andrew
  • Cummings, Kyle Frank
  • Budge, Dan

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The system may also include an encoder configured to generate a signal indicative of an amount of material passing through the print head, and a controller in communication with the encoder. The controller may be configured to selectively implement a corrective action in response to the signal.

IPC Classes  ?

  • B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/321 - Feeding
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/268 - Arrangements for irradiation using electron beams [EB]
  • B29C 64/314 - Preparation
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B22F 10/10 - Formation of a green body

37.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 17660133
Grant Number 11865775
Status In Force
Filing Date 2022-04-21
First Publication Date 2022-08-04
Grant Date 2024-01-09
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

38.

System for additively manufacturing composite structure

      
Application Number 17654090
Grant Number 11958245
Status In Force
Filing Date 2022-03-09
First Publication Date 2022-06-23
Grant Date 2024-04-16
Owner Continuous Composites Inc. (USA)
Inventor Stranberg, Nathan Andrew

Abstract

A system is disclosed that includes an end effector and a support configured to move the end effector. The support may include a first link, a second link rotationally connected to the first link at a joint, and a motor rigidly mounted to the first link and configured to drive rotation of the second link relative to the first link. The support may also include a sole encoder associated with the joint and configured to generate a signal indicative of a position of the first link relative to the second link. The system may further include a controller in communication with the sole encoder and the motor. The controller may be configured to selectively trim operation of the motor based only on the signal.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B22F 10/10 - Formation of a green body
  • B22F 10/18 - Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
  • B22F 10/50 - Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
  • B22F 10/80 - Data acquisition or data processing
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
  • B22F 12/53 - Nozzles
  • B22F 12/63 - Rollers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/218 - Rollers
  • B29C 64/227 - Driving means
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber

39.

System for additively manufacturing composite structure

      
Application Number 17654033
Grant Number 11485070
Status In Force
Filing Date 2022-03-08
First Publication Date 2022-06-16
Grant Date 2022-11-01
Owner Continuous Composites Inc. (USA)
Inventor Stranberg, Nathan Andrew

Abstract

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and an outlet configured to discharge a material. The outlet may be operatively connected to and moveable by the support in a normal travel direction during material discharge. The outlet may include a guide, and a compactor operatively connected to the guide at a trailing location relative to the normal travel direction. The compactor may be moveable in an axial direction of the guide. The outlet may also include at least one cure enhancer mounted to move with the compactor relative to the guide. The at least one cure enhancer may be configured to expose the material to a cure energy.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/218 - Rollers
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/314 - Preparation
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B29C 64/227 - Driving means
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

40.

SYSTEM FOR ADDITIVE MANUFACTURING

      
Application Number 17652376
Status Pending
Filing Date 2022-02-24
First Publication Date 2022-06-09
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Overby, Andrew John
  • Hambling, Colin Hugh

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, a discharge head connected to and moveable by the support, a supply of reinforcement, and a rotary tensioner located between the supply and the discharge head. The rotary tensioner may be configured to impart tension to the reinforcement and to generate a signal indicative of the tension. The system may further include a drive associated with the supply, and a controller in communication with the rotary tensioner and the drive. The controller may be configured to selectively adjust a feed parameter of the drive based on the signal to maintain a desired level of tension.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/321 - Feeding
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]

41.

System for additive manufacturing

      
Application Number 17645405
Grant Number 11806923
Status In Force
Filing Date 2021-12-21
First Publication Date 2022-04-21
Grant Date 2023-11-07
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Stranberg, Nathan Andrew
  • Stockett, Ryan C
  • Stulc, Andrew Michael

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may have an outlet configured to discharge a continuous reinforcement at least partially coated in a matrix, and a device located inside the print head and configured to at least partially coat the continuous reinforcement with the matrix. The system may also include a sensor configured to generate a signal indicative of an amount of the matrix, and a controller in communication with the sensor and the device. The controller may be configured to direct a command to the device to cause the device to advance matrix toward the continuous reinforcement during passage of the continuous reinforcement through the print head, and to selectively adjust the command based on the signal.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/295 - Heating elements
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B22F 10/20 - Direct sintering or melting
  • B22F 12/53 - Nozzles
  • B29K 101/10 - Thermosetting resins
  • B33Y 10/00 - Processes of additive manufacturing
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices

42.

Additive manufacturing system and method

      
Application Number 17451591
Grant Number 11548220
Status In Force
Filing Date 2021-10-20
First Publication Date 2022-04-21
Grant Date 2023-01-10
Owner Continuous Composites Inc. (USA)
Inventor
  • Alvarado, Tyler B.
  • Jahner, Brock Adam
  • Overby, Andrew John
  • Smith, Jeremiah R.
  • Stockett, Ryan C.
  • Stranberg, Nathan Andrew

Abstract

A method is disclosed for additively manufacturing a composite structure. The method may include discharging a composite material from a print head and moving the print head during discharging to fabricate a preform from the composite material. The method may also include densifying the preform with a densifying material, and heating the preform to pyrolize the at least one of the composite material and the densifying material.

IPC Classes  ?

  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/295 - Heating elements
  • B29C 64/321 - Feeding
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29L 15/00 - Gear wheels or similar articles with grooves or projections, e.g. control knobs

43.

System for additive manufacturing

      
Application Number 17645114
Grant Number 11607839
Status In Force
Filing Date 2021-12-20
First Publication Date 2022-04-14
Grant Date 2023-03-21
Owner Continuous Composites Inc. (USA)
Inventor
  • Stockett, Ryan C
  • Alvarado, Tyler B.
  • Wilson, Stephen Tyler

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may have a first tool center point associated with discharge of a first material, and a second tool center point associated with discharge of a second material that is a type different than the first material.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/295 - Heating elements
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B22F 10/20 - Direct sintering or melting
  • B22F 12/53 - Nozzles
  • B29K 101/10 - Thermosetting resins
  • B33Y 10/00 - Processes of additive manufacturing
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices

44.

System for additively manufacturing composite structures

      
Application Number 17457941
Grant Number 11760013
Status In Force
Filing Date 2021-12-07
First Publication Date 2022-03-24
Grant Date 2023-09-19
Owner Continuous Composites Inc. (USA)
Inventor
  • Hambling, Colin Hugh
  • Budge, Trevor David
  • Stockett, Ryan C.

Abstract

A method is disclosed for additively manufacturing an object. The method may include discharging a composite material from a print head to form the object. The method may also include drawing out fewer than all components of the composite material from the print head prior to discharging.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/241 - Driving means for rotary motion
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material

45.

System for additively manufacturing composite structures

      
Application Number 17457942
Grant Number 11787112
Status In Force
Filing Date 2021-12-07
First Publication Date 2022-03-24
Grant Date 2023-10-17
Owner Continuous Composites Inc. (USA)
Inventor
  • Hambling, Colin Hugh
  • Budge, Trevor David
  • Stockett, Ryan C

Abstract

A system is disclosed for additively manufacturing an object. The system may include a support, and a print head having an outlet and being connected to and moveable by the support in a normal travel direction during discharge of material from the print head. The system may also include a first device operatively connected to the print head at a trailing location relative to the normal travel direction. The first device may be configured to expose the material to a cure energy. The system may further have a second device operatively connected to the print head at a location trailing the first device relative to the travel direction. The second trailing device configured to expose the material to a cure energy.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/241 - Driving means for rotary motion
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material

46.

System for additively manufacturing composite structures

      
Application Number 17457938
Grant Number 11752696
Status In Force
Filing Date 2021-12-07
First Publication Date 2022-03-24
Grant Date 2023-09-12
Owner Continuous Composites Inc. (USA)
Inventor
  • Hambling, Colin Hugh
  • Budge, Trevor David
  • Stockett, Ryan C.

Abstract

A head is disclosed for an additive manufacturing system. The head may include a first outlet configured to discharge a composite material to form an object. The head may also include a second outlet located upstream of the first outlet and configured to discharge fewer than all components of the composite material.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/241 - Driving means for rotary motion
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material

47.

Print head for additive manufacturing system

      
Application Number 17443421
Grant Number 11465348
Status In Force
Filing Date 2021-07-26
First Publication Date 2022-03-17
Grant Date 2022-10-11
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Jahner, Brock Adam
  • Smith, Jeremiah R.
  • Stranberg, Nathan Andrew
  • Stulc, Andrew Michael
  • Vandenberg, Samuel
  • Wilson, Stephen Tyler
  • Overby, Andrew John

Abstract

A system is disclosed for additively manufacturing a composite structure. 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 of continuous reinforcement, an outlet configured to discharge the continuous reinforcement, and a tensioning module disposed between the supply and outlet. The tensioning module may be configured to generate a signal indicative of a tension in the continuous reinforcement. The system may also include a processor programmed to selectively cause the supply to dispense the continuous reinforcement based on the signal.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/343 - Metering
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/314 - Preparation
  • B29C 64/295 - Heating elements
  • B33Y 40/10 - Pre-treatment
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

48.

Print head for additive manufacturing system

      
Application Number 17443942
Grant Number 11541598
Status In Force
Filing Date 2021-07-28
First Publication Date 2022-03-17
Grant Date 2023-01-03
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Jahner, Brock Adam
  • Smith, Jeremiah R.
  • Stranberg, Nathan Andrew
  • Stulc, Andrew Michael
  • Vandenberg, Samuel
  • Wilson, Stephen Tyler
  • Overby, Andrew John

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/343 - Metering
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/314 - Preparation
  • B29C 64/295 - Heating elements
  • B33Y 40/10 - Pre-treatment
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

49.

Print head for additive manufacturing system

      
Application Number 17443423
Grant Number 11813793
Status In Force
Filing Date 2021-07-26
First Publication Date 2022-03-17
Grant Date 2023-11-14
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Jahner, Brock Adam
  • Smith, Jeremiah R.
  • Stranberg, Nathan Andrew
  • Stulc, Andrew Michael
  • Vandenberg, Samuel
  • Wilson, Stephen Tyler
  • Overby, Andrew John

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a continuous reinforcement, a second supply configured to hold a matrix separate from the continuous reinforcement, and a wetting mechanism in separate communication with the first and second supplies and configured to discharge the continuous reinforcement wetted with the matrix. The system may also include a controller programmed to selectively pressurize the second supply to direct the matrix to the wetting mechanism.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/343 - Metering
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/314 - Preparation
  • B29C 64/295 - Heating elements
  • B33Y 40/10 - Pre-treatment
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

50.

Print head for additive manufacturing system

      
Application Number 17443425
Grant Number 11613080
Status In Force
Filing Date 2021-07-26
First Publication Date 2022-03-17
Grant Date 2023-03-28
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Jahner, Brock Adam
  • Smith, Jeremiah R.
  • Stranberg, Nathan Andrew
  • Stulc, Andrew Michael
  • Vandenberg, Samuel
  • Wilson, Stephen Tyler
  • Overby, Andrew John

Abstract

A system is disclosed for additively manufacturing a composite structure. 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 in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/343 - Metering
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/314 - Preparation
  • B29C 64/295 - Heating elements
  • B33Y 40/10 - Pre-treatment
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

51.

PRINT HEAD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17443428
Status Pending
Filing Date 2021-07-26
First Publication Date 2022-03-17
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Jahner, Brock Adam
  • Smith, Jeremiah R.
  • Stranberg, Nathan Andrew
  • Stulc, Andrew Michael
  • Vandenberg, Samuel
  • Wilson, Stephen Tyler
  • Overby, Andrew John

Abstract

A system is disclosed for additively manufacturing a composite structure. 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 in a trajectory along a central axis of the outlet; a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface, and a cutting module located between the outlet and the compactor. The compactor and the cutting module may be configured to move together relative to the outlet.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects

52.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 17453313
Grant Number 11590699
Status In Force
Filing Date 2021-11-02
First Publication Date 2022-03-10
Grant Date 2023-02-28
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

53.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 17453309
Grant Number 11584069
Status In Force
Filing Date 2021-11-02
First Publication Date 2022-03-10
Grant Date 2023-02-21
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

54.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 17481147
Grant Number 11945160
Status In Force
Filing Date 2021-09-21
First Publication Date 2022-01-06
Grant Date 2024-04-02
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing

55.

SYSTEMS AND METHODS FOR CONTROLLING ADDITIVE MANUFACTURING

      
Application Number 17304031
Status Pending
Filing Date 2021-06-14
First Publication Date 2021-12-23
Owner Continuous Composites Inc. (USA)
Inventor
  • Lalonde, Logan
  • Jahner, Brock Adam
  • Negugogor, Mikel
  • Morris, Rachael Kathleen

Abstract

A method is disclosed for additively manufacturing a composite structure. The method may include receiving from a user a sketch of a cross-section of the composite structure and a desired height. The method may also include automatically generating a virtual model of the composite structure having a plurality of layers, each with a thickness related to the height. The method may further include receiving from the user at least one infill pattern for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a continuous fiber along segments of the at least one infill pattern.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06F 30/10 - Geometric CAD
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]

56.

Systems and methods for controlling additive manufacturing

      
Application Number 17304032
Grant Number 11760029
Status In Force
Filing Date 2021-06-14
First Publication Date 2021-12-23
Grant Date 2023-09-19
Owner Continuous Composites Inc. (USA)
Inventor
  • Lalonde, Logan
  • Jahner, Brock Adam
  • Negugogor, Mikel
  • Morris, Rachael Kathleen

Abstract

A method is disclosed for additively manufacturing a structure. The method may include generating a vector field through a 3D virtual model, and slicing the virtual model into a plurality of layers that are aligned with the vector field. The method may also include generating at least one tool path for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a material along the at least one tool path.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06F 30/10 - Geometric CAD
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/227 - Driving means
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

57.

Systems and methods for controlling additive manufacturing

      
Application Number 17304033
Grant Number 11760030
Status In Force
Filing Date 2021-06-14
First Publication Date 2021-12-23
Grant Date 2023-09-19
Owner Continuous Composites Inc. (USA)
Inventor
  • Lalonde, Logan
  • Jahner, Brock Adam
  • Negugogor, Mikel
  • Morris, Rachael Kathleen

Abstract

A method is disclosed for additively manufacturing a structure. The method may include generating at least one tool path, causing the additive manufacturing machine to place material along a first portion of the at least one tool path, and monitoring placement of the material along the first portion of the at least one tool path. The method may also include adjusting a second portion of the at least one tool path based on the placement, and causing the additive manufacturing machine to place material along the second portion of the at least one tool path after the adjusting.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/227 - Driving means
  • G06F 30/10 - Geometric CAD
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

58.

Systems and methods for controlling additive manufacturing

      
Application Number 17304034
Grant Number 11926100
Status In Force
Filing Date 2021-06-14
First Publication Date 2021-12-23
Grant Date 2024-03-12
Owner Continuous Composites Inc. (USA)
Inventor
  • Lalonde, Logan
  • Jahner, Brock Adam
  • Negugogor, Mikel
  • Morris, Rachael Kathleen

Abstract

A method is disclosed for additively manufacturing a structure. The method may include slicing a virtual model of the structure into a plurality of layers, applying at least one infill pattern to each of the plurality of layers, and distributing a plurality of points along lines of the at least one infill pattern. The method may also include sequentially grouping the plurality of points into at least one path, validating the at least one path for fabrication by an additive manufacturing machine, and causing the additive manufacturing machine to discharge material along the validated at least one path.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/227 - Driving means
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • G06F 30/10 - Geometric CAD
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing

59.

IN-SITU CURING OVEN FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 17445547
Status Pending
Filing Date 2021-08-20
First Publication Date 2021-12-09
Owner Continuous Composites Inc. (USA)
Inventor
  • Stockett, Ryan C.
  • Tyler, Kenneth Lyle

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement that is at least partially coated with a matrix, and a housing trailing from the head and configured to at least partially enclose the continuous reinforcement after discharge. The system may also include a heat source disposed at least partially inside the oven, and a support configured to move the head during discharging.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/52 - Pultrusion, i.e. forming and compressing by continuously pulling through a die
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 70/50 - Shaping or impregnating by compression for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
  • B29C 70/24 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
  • B29C 64/218 - Rollers
  • B29C 64/336 - Feeding of two or more materials
  • B29C 70/16 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/295 - Heating elements
  • B29C 64/291 - Arrangements for irradiation for operating globally, e.g. together with selectively applied activators or inhibitors
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof

60.

System for continuously manufacturing composite structure

      
Application Number 17443265
Grant Number 11958243
Status In Force
Filing Date 2021-07-23
First Publication Date 2021-11-11
Grant Date 2024-04-16
Owner Continuous Composites Inc. (USA)
Inventor
  • Stuart, Nathaniel Isaak
  • Alvarado, Tyler B.
  • Stockett, Ryan C.

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include at least one support, and a print head operatively connected to the at least one support and configured to discharge composite material. The system may further include an auxiliary tool operatively connected to the at least one support and configured to receive the composite material discharged by the print head.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

61.

RESPIRATOR HAVING REPLACEABLE FILTRATION MEDIUM

      
Application Number 17301172
Status Pending
Filing Date 2021-03-29
First Publication Date 2021-11-11
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Overby, Andrew John

Abstract

A respirator is disclosed for use in protecting a wearer from airborne contaminates. The respirator may include a body configured to seal against a face of a wearer and provide clearance for a nose, a mouth, and a chin of the wearer. The respirator may also include a frame connectable to the body. At least one of the body and the frame may be configured to receive and seal against a plurality of filter media having different shapes.

IPC Classes  ?

  • A62B 23/02 - Filters for breathing-protection purposes for respirators
  • A41D 13/11 - Protective face masks, e.g. for surgical use, or for use in foul atmospheres

62.

Additive manufacturing system

      
Application Number 17249661
Grant Number 11472104
Status In Force
Filing Date 2021-03-09
First Publication Date 2021-09-30
Grant Date 2022-10-18
Owner Continuous Composites Inc. (USA)
Inventor Overby, Andrew John

Abstract

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head configured to discharge a material, a first structure, and a second structure. The first structure may be configured to move the print head within a plane during discharge of the material. The second structure may be configured to move the print head within the plane during material discharge, the second structure being movable together with the print head by the first structure.

IPC Classes  ?

  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/209 - Heads; Nozzles
  • B25J 9/02 - Programme-controlled manipulators characterised by movement of the arms, e.g. cartesian co-ordinate type

63.

System, print head, and compactor for continuously manufacturing composite structure

      
Application Number 17303107
Grant Number 11623394
Status In Force
Filing Date 2021-05-20
First Publication Date 2021-09-16
Grant Date 2023-04-11
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Tyler, Kenneth Lyle
  • Hambling, Colin Hugh

Abstract

A compactor is disclosed for use with an additive manufacturing print head. The compactor may include a housing connectable to the additive manufacturing print head. The compactor may also include a compacting wheel, and at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel. The compactor may further include a piston moveable to adjust a distance between the housing and the compacting wheel.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B22F 10/18 - Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • B22F 12/50 - Means for feeding of material, e.g. heads
  • B22F 12/53 - Nozzles
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
  • B22F 12/42 - Light-emitting diodes [LED]
  • B22F 12/46 - Radiation means with translatory movement
  • B29K 105/06 - Condition, form or state of moulded material containing reinforcements, fillers or inserts

64.

System, print head, and compactor for continuously manufacturing composite structure

      
Application Number 17303102
Grant Number 11623393
Status In Force
Filing Date 2021-05-20
First Publication Date 2021-09-16
Grant Date 2023-04-11
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Tyler, Kenneth Lyle
  • Hambling, Colin Hugh

Abstract

A compactor is disclosed for use with an additive manufacturing print head. The compactor may include a housing connectable to the additive manufacturing print head. The compactor may also include a compacting wheel, and at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel. The compactor may further include a piston moveable to adjust a distance between the housing and the compacting wheel.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B22F 10/18 - Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • B22F 12/50 - Means for feeding of material, e.g. heads
  • B22F 12/53 - Nozzles
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
  • B22F 12/42 - Light-emitting diodes [LED]
  • B22F 12/46 - Radiation means with translatory movement
  • B29K 105/06 - Condition, form or state of moulded material containing reinforcements, fillers or inserts

65.

Additive manufacturing system

      
Application Number 17249225
Grant Number 11904534
Status In Force
Filing Date 2021-02-24
First Publication Date 2021-08-26
Grant Date 2024-02-20
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Stulc, Andrew Michael
  • Jahner, Brock Adam
  • Wilson, Stephen Tyler

Abstract

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a housing, a supply module operatively mounted to the housing and configured to hold a supply of continuous reinforcement, an impregnation module operatively mounted to the housing and configured to wet the continuous reinforcement with a matrix, and a clamping module operatively mounted to the housing downstream of the supply module relative to movement of a reinforcement through the print head. The clamping module may be configured to selectively clamp the continuous reinforcement. The additive manufacturing system may also include a controller in communication with the support and the print head and configured to coordinate operations of the support and the print head to fabricate a three-dimensional structure.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/336 - Feeding of two or more materials
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/209 - Heads; Nozzles
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 40/10 - Pre-treatment
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

66.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 17301639
Grant Number 11173660
Status In Force
Filing Date 2021-04-09
First Publication Date 2021-07-22
Grant Date 2021-11-16
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

67.

System and method for additive manufacturing

      
Application Number 16949300
Grant Number 11840022
Status In Force
Filing Date 2020-10-23
First Publication Date 2021-07-01
Grant Date 2023-12-12
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Dan
  • Negugogor, Mikel
  • Morris, Rachael Kathleen

Abstract

A method is disclosed for use in additively manufacturing a composite structure from reinforcements wetted with a matrix. The method may include slicing a virtual model of the composite structure into multiple slices that are adjacent to each other along a length direction of the composite structure and determining points of the reinforcements passing through each of the multiple slices. The method may further include clocking the points differently around each of the multiple slices and generating at least one tool path including a sequenced subset of the points. The method may additionally include causing an additive manufacturing machine to discharge the reinforcements along the at least one tool path.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing

68.

Systems and methods for controlling additive manufacturing

      
Application Number 16948866
Grant Number 11579579
Status In Force
Filing Date 2020-10-02
First Publication Date 2021-03-11
Grant Date 2023-02-14
Owner Continuous Composites Inc. (USA)
Inventor
  • Stockett, Ryan C
  • Tyler, Kenneth L.
  • Alfson, Blake L.
  • Coad, Josiah D.

Abstract

A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to determine a plurality of tension vectors to be generated within the structure, and to generate a plan for manufacturing the structure. The plan may include tool paths that arrange continuous fibers within the structure to generate the plurality of tension vectors. The processor may also be configured to execute the computer-executable instructions to cause the additive manufacturing machine to follow the plan and manufacture the structure.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • G05B 19/042 - Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing

69.

System for additively manufacturing composite structure

      
Application Number 16880398
Grant Number 11541603
Status In Force
Filing Date 2020-05-21
First Publication Date 2020-12-03
Grant Date 2023-01-03
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Wilson, Stephen Tyler
  • Vandenberg, Samuel

Abstract

A print head is disclosed for use in an additive manufacturing system. The print head may include an outlet configured to discharge a material, and a compacting device mounted to trail behind the outlet during movement of the print head in a normal direction. The print head may also include a spring configured to bias the compacting device against the material and to allow movement of the compacting device in a direction parallel with a discharge direction of the material through the outlet, and a locker configured to selectively lock a position of the compacting device relative to the outlet.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/241 - Driving means for rotary motion
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/227 - Driving means
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B22F 10/10 - Formation of a green body

70.

System for additively manufacturing composite structure

      
Application Number 16842420
Grant Number 11312083
Status In Force
Filing Date 2020-04-07
First Publication Date 2020-12-03
Grant Date 2022-04-26
Owner Continuous Composites Inc. (USA)
Inventor Stranberg, Nathan Andrew

Abstract

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head, and a support configured to move the print head. The support may include a first link, a second link rotationally connected to the first link at a joint, and an encoder-less motor rigidly mounted to the first link and configured to drive rotation of the second link relative to the first link. The support may also include a sole encoder associated with the joint and configured to generate a signal indicative of an angular position of the first link relative to the second link. The additive manufacturing system may further include a controller in communication with the sole encoder and the encoder-less motor. The controller may be configured to selectively trim operation of the encoder-less motor based only on the signal.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/241 - Driving means for rotary motion
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B22F 10/10 - Formation of a green body
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/227 - Driving means
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots

71.

Composite vehicle body

      
Application Number 16947661
Grant Number 11383819
Status In Force
Filing Date 2020-08-11
First Publication Date 2020-11-26
Grant Date 2022-07-12
Owner Continuous Composites Inc. (USA)
Inventor
  • Stockett, Ryan C.
  • Tyler, Kenneth L.

Abstract

A vehicle body may have an internal skeleton forming a wing shape, and a skin formed over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. The plurality of continuous fibers may curve from a base end near a fore/aft center of the wing shape outward toward leading and trailing edges of the wing shape at a tip end.

IPC Classes  ?

  • B64C 1/12 - Construction or attachment of skin panels
  • B29C 64/336 - Feeding of two or more materials
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B64C 1/06 - Frames; Stringers; Longerons
  • B64C 3/34 - Tanks constructed integrally with wings, e.g. for fuel or water
  • B64C 1/08 - Geodetic or other open-frame structures
  • B29C 70/56 - Tensioning reinforcements before or during shaping
  • B29D 99/00 - Subject matter not provided for in other groups of this subclass
  • B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
  • B64C 3/26 - Construction, shape, or attachment of separate skins, e.g. panels
  • B33Y 80/00 - Products made by additive manufacturing
  • B64C 1/26 - Attaching the wing or tail units or stabilising surfaces
  • B64F 5/10 - Manufacturing or assembling aircraft, e.g. jigs therefor
  • B29C 70/30 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
  • B64C 3/18 - Spars; Ribs; Stringers
  • B64C 3/20 - Integral or sandwich constructions
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
  • B29K 101/10 - Thermosetting resins
  • B62D 29/04 - Superstructures characterised by material thereof predominantly of synthetic material
  • B64C 1/00 - Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like

72.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 16946469
Grant Number 11577455
Status In Force
Filing Date 2020-06-23
First Publication Date 2020-10-15
Grant Date 2023-02-14
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

73.

System for additively manufacturing composite structure

      
Application Number 16744415
Grant Number 11618208
Status In Force
Filing Date 2020-01-16
First Publication Date 2020-07-30
Grant Date 2023-04-04
Owner Continuous Composites Inc. (USA)
Inventor Stranberg, Nathan Andrew

Abstract

An additive manufacturing system is disclosed for use in discharging a continuous reinforcement. The additive manufacturing system may include a support, and a compactor operatively connected to and movable by the support. The compactor may be configured to apply a pressure to the continuous reinforcement during discharge. The additive manufacturing system may also include a feed roller biased toward the compactor to sandwich the continuous reinforcement between the roller and the compactor, and a cutting mechanism at least partially recessed within at least one of the feed roller and the compactor. The cutting mechanism may be configured to selectively move radially outward to engage the continuous reinforcement.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/218 - Rollers
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/314 - Preparation
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B29C 64/227 - Driving means
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

74.

System for additively manufacturing composite structure

      
Application Number 16744902
Grant Number 11478980
Status In Force
Filing Date 2020-01-16
First Publication Date 2020-07-30
Grant Date 2022-10-25
Owner Continuous Composites Inc. (USA)
Inventor
  • Morris, Rachael Kathleen
  • Stockett, Ryan C.

Abstract

A system is disclosed for use in additively manufacturing a structure. The system may include a print head configured to discharge a material, and a support connected to and configured to move the print head during discharging to fabricate a structure. The system may also include a receiver mounted to the print head and configured to generate a signal indicative of at least one of a shape, a size, and a location of the discharged material, and a processor in communication with the receiver and the support. The processor may be configured to generate a data cloud of the structure fabricated by the additive manufacturing system based on the signal and based on a known position of the receiver at a time of signal generation. The processor may also be configured to make a comparison of the data cloud and a virtual model of the structure during discharging, and to selectively affect discharging based on the comparison.

IPC Classes  ?

  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/218 - Rollers
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/314 - Preparation
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B29C 64/227 - Driving means
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

75.

System for additively manufacturing composite structure

      
Application Number 16842611
Grant Number 11420390
Status In Force
Filing Date 2020-04-07
First Publication Date 2020-07-30
Grant Date 2022-08-23
Owner Continuous Composites Inc. (USA)
Inventor
  • Brodie, Marcus Raye Vincent
  • Cummings, Kyle Frank
  • Stulc, Andrew Michael
  • Stranberg, Nathan Andrew
  • Jahner, Brock
  • Wilson, Stephen Tyler

Abstract

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head configured to discharge a material and being operatively connected to and moveable by the support in a normal travel direction during material discharge. The print head may include a module located at a trailing side of the discharging material relative to the normal travel direction and being configured to compact the material and expose the material to a cure energy at a tool center point.

IPC Classes  ?

  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/264 - Arrangements for irradiation
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

76.

System for additively manufacturing composite structure

      
Application Number 16744937
Grant Number 11400643
Status In Force
Filing Date 2020-01-16
First Publication Date 2020-07-30
Grant Date 2022-08-02
Owner Continuous Composites Inc. (USA)
Inventor
  • Wilson, Stephen Tyler
  • Stockett, Ryan C.

Abstract

A system for additively manufacturing a structure is disclosed. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may have an outlet that is oriented at an oblique angle relative to a central axis of the print head.

IPC Classes  ?

  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/218 - Rollers
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/314 - Preparation
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B29C 64/227 - Driving means
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing

77.

System for additively manufacturing composite structure

      
Application Number 16752257
Grant Number 11338503
Status In Force
Filing Date 2020-01-24
First Publication Date 2020-07-30
Grant Date 2022-05-24
Owner Continuous Composites Inc. (USA)
Inventor Stranberg, Nathan Andrew

Abstract

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and an outlet configured to discharge a material. The outlet may be operatively connected to and moveable by the support in a normal travel direction during material discharge. The outlet may include a guide, and a compactor operatively connected to the guide at a trailing location relative to the normal travel direction. The compactor may be moveable in an axial direction of the guide. The outlet may also include at least one cure enhancer mounted to move with the compactor relative to the guide. The at least one cure enhancer may be configured to expose the material to a cure energy.

IPC Classes  ?

  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/218 - Rollers
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/314 - Preparation
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B29C 64/227 - Driving means
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

78.

Control methods for additive manufacturing system

      
Application Number 16814972
Grant Number 11161297
Status In Force
Filing Date 2020-03-10
First Publication Date 2020-07-02
Grant Date 2021-11-02
Owner Continuous Composites Inc. (USA)
Inventor
  • Tyler, Kenneth Lyle
  • Alfson, Blake L.
  • Coad, Josiah D.
  • Beebout, Kaleb Forrest

Abstract

A method is disclosed for controlling an additive manufacturing system. The method may include causing a head to discharge composite material along a first trajectory, and activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory. The method may also include selectively deactivating the cure enhancer as the head nears a corner location, moving the head to a second trajectory after the head reaches the corner location, and reactivating the cure enhancer after moving the head to the second trajectory.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

79.

System for additive manufacturing

      
Application Number 16660519
Grant Number 11292192
Status In Force
Filing Date 2019-10-22
First Publication Date 2020-05-21
Grant Date 2022-04-05
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Overby, Andrew John
  • Hambling, Colin Hugh

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, a discharge head connected to and moveable by the support, a supply of reinforcement, and a rotary tensioner located between the supply and the discharge head. The rotary tensioner may be configured to impart tension to the reinforcement and to generate a signal indicative of the tension. The system may further include a drive associated with the supply, and a controller in communication with the rotary tensioner and the drive. The controller may be configured to selectively adjust a feed parameter of the drive based on the signal to maintain a desired level of tension.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/321 - Feeding
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

80.

System and head for continuously manufacturing composite structure

      
Application Number 16516113
Grant Number 11358331
Status In Force
Filing Date 2019-07-18
First Publication Date 2020-05-21
Grant Date 2022-06-14
Owner Continuous Composites inc. (USA)
Inventor
  • Cummings, Kyle Frank
  • Brodie, Marcus Raye Vincent
  • Vandenberg, Samuel
  • Stockett, Ryan C.

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to discharge a continuous reinforcement that is at least partially coated in a matrix, and a compactor configured to compact the continuous reinforcement and the matrix. The system may also include a cure enhancer configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor.

IPC Classes  ?

  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber

81.

System for additive manufacturing

      
Application Number 16596397
Grant Number 11247395
Status In Force
Filing Date 2019-10-08
First Publication Date 2020-04-30
Grant Date 2022-02-15
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Stranberg, Nathan Andrew
  • Stockett, Ryan C.
  • Stulc, Andrew Michael

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may have an outlet configured to discharge a continuous reinforcement at least partially coated in a matrix. The system may also include at least one doser located inside the print head and configured to at least partially coat the continuous reinforcement with the matrix, a sensor located downstream of the at least one doser and configured to generate a signal indicative of an amount of matrix coating the continuous reinforcement, and a controller in communication with the sensor and the at least one doser. The controller may be configured to direct a feedforward command to the at least one doser to cause the at least one doser to advance matrix toward the continuous reinforcement during passage of the continuous reinforcement through the print head, and to selectively adjust the feedforward command based on the signal.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/295 - Heating elements
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 70/54 - Component parts, details or accessories; Auxiliary operations
  • B29K 101/10 - Thermosetting resins
  • B33Y 10/00 - Processes of additive manufacturing

82.

System and method for additive manufacturing

      
Application Number 16584068
Grant Number 11325304
Status In Force
Filing Date 2019-09-26
First Publication Date 2020-04-30
Grant Date 2022-05-10
Owner Continuous Composites Inc. (USA)
Inventor
  • Stranberg, Nathan Andrew
  • Budge, Dan
  • Stockett, Ryan C.

Abstract

A method is disclosed for operating an additive manufacturing system. The method may include wetting a reinforcement with a thermoset matrix inside of a print head, discharging the wetted reinforcement from the print head, and moving the print head in multiple directions during discharging. The method may also include exposing the thermoset matrix wetting the reinforcement to a cure energy to initiate a chemical reaction, and directing a medium onto the wetted reinforcement to regulate a rate of the chemical reaction.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 70/54 - Component parts, details or accessories; Auxiliary operations
  • B29C 64/295 - Heating elements
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29K 101/10 - Thermosetting resins
  • B33Y 10/00 - Processes of additive manufacturing

83.

System for additive manufacturing

      
Application Number 16584196
Grant Number 11511480
Status In Force
Filing Date 2019-09-26
First Publication Date 2020-04-30
Grant Date 2022-11-29
Owner Continuous Composites Inc. (USA)
Inventor
  • Morris, Rachael Kathleen
  • Stockett, Ryan C.

Abstract

A system is disclosed for additive manufacturing of a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may include an outlet configured to discharge a continuous reinforcement at least partially coated in a matrix. The outlet may be moveable relative to the support. The print head may also include at least one actuator configured to cause movement of the outlet relative to the support.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/295 - Heating elements
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29K 101/10 - Thermosetting resins
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

84.

Additive manufacturing system having in-head fiber-teasing

      
Application Number 16705069
Grant Number 10994481
Status In Force
Filing Date 2019-12-05
First Publication Date 2020-04-09
Grant Date 2021-05-04
Owner Continuous Composites Inc. (USA)
Inventor
  • Tyler, Kenneth Lyle
  • Stockett, Ryan C.
  • Beebout, Kaleb Forrest

Abstract

A head is disclosed for an additive manufacturing system having a support. The head may include a body connectable to and moveable by the support. The body may have a discharge end configured to discharge a composite material. The head may also include a wetting location inside the body at which a continuous reinforcement is wetted with a matrix to form the composite material, and a fiber-teasing mechanism located inside the body and upstream of the discharge end and the wetting location. The body and fiber-teasing mechanism may be configured to move together during movement of the support.

IPC Classes  ?

  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

85.

System for additively manufacturing composite structures

      
Application Number 16546288
Grant Number 11235522
Status In Force
Filing Date 2019-08-20
First Publication Date 2020-04-09
Grant Date 2022-02-01
Owner Continuous Composites Inc. (USA)
Inventor
  • Hambling, Colin Hugh
  • Budge, Trevor David
  • Stockett, Ryan C.

Abstract

A head is disclosed for an additive manufacturing system. The head may include an outlet configured to discharge a continuous reinforcement at least partially coated in a liquid matrix. The head may also include a low-pressure port located upstream of the outlet and configured to draw out only liquid matrix.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/241 - Driving means for rotary motion
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material

86.

Additive manufacturing system having in-head fiber-teasing

      
Application Number 16705186
Grant Number 11000998
Status In Force
Filing Date 2019-12-05
First Publication Date 2020-04-09
Grant Date 2021-05-11
Owner Continous Composites Inc. (USA)
Inventor
  • Tyler, Kenneth Lyle
  • Stockett, Ryan C.
  • Beebout, Kaleb Forrest

Abstract

A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, spreading the continuous reinforcement while inside of the print head, and wetting the continuous reinforcement inside of the print head. The method may also include discharging the wetted continuous reinforcement, and moving the print head during discharging.

IPC Classes  ?

  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

87.

System for additively manufacturing composite structures

      
Application Number 16531055
Grant Number 11338528
Status In Force
Filing Date 2019-08-03
First Publication Date 2020-03-19
Grant Date 2022-05-24
Owner Continouos Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Stranberg, Nathan Andrew
  • Cummings, Kyle Frank
  • Budge, Dan

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The system may also include an encoder configured to generate a signal indicative of an amount of material passing through the print head, and a controller in communication with the encoder. The controller may be configured to selectively implement a corrective action in response to the signal.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/321 - Feeding
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/268 - Arrangements for irradiation using electron beams [EB]
  • B29C 64/314 - Preparation
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B22F 10/10 - Formation of a green body
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

88.

Fiber management arrangement and method for additive manufacturing system

      
Application Number 16516119
Grant Number 11235539
Status In Force
Filing Date 2019-07-18
First Publication Date 2020-03-19
Grant Date 2022-02-01
Owner Continuous Composites Inc. (USA)
Inventor
  • Hambling, Colin Hugh
  • Budge, Trevor David

Abstract

A method is disclosed for severing a continuous reinforcement from a print head at conclusion of an event during fabrication of a composite structure. The method may include moving the print head a distance away from the composite structure that provides clearance for a cutting mechanism between an outlet of the print head and the composite structure, and responsively causing the cutting mechanism to make a first cut of the continuous reinforcement at a boundary of the composite structure. The method may also include moving the print head to a waste discard location, and responsively causing the cutting mechanism to make a second cut of the continuous reinforcement at a desired distance offset from the outlet of the print head.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/321 - Feeding
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/268 - Arrangements for irradiation using electron beams [EB]
  • B29C 64/314 - Preparation
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B22F 10/10 - Formation of a green body
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

89.

Additive manufacturing system

      
Application Number 16537902
Grant Number 10843396
Status In Force
Filing Date 2019-08-12
First Publication Date 2020-01-02
Grant Date 2020-11-24
Owner Continuous Composites Inc. (USA)
Inventor
  • Tyler, Kenneth Lyle
  • Stockett, Ryan C.

Abstract

A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.

IPC Classes  ?

  • B29C 71/02 - Thermal after-treatment
  • B29C 71/04 - After-treatment of articles without altering their shape; Apparatus therefor by wave energy or particle radiation
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B29C 48/12 - Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/371 - Conditioning of environment using an environment other than air, e.g. inert gas
  • B29C 48/08 - Flat, e.g. panels flexible, e.g. films
  • B29C 48/35 - Extrusion nozzles or dies with rollers
  • B29C 48/305 - Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
  • B29C 64/245 - Platforms or substrates
  • B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
  • B29C 70/24 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 70/68 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers
  • B29C 48/05 - Filamentary, e.g. strands
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/277 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29C 64/282 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/214 - Doctor blades
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/336 - Feeding of two or more materials
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 64/218 - Rollers
  • B29K 105/10 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns oriented
  • B29K 105/00 - Condition, form or state of moulded material
  • B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B29C 33/00 - 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 - Details thereof or accessories therefor
  • B33Y 80/00 - Products made by additive manufacturing
  • B22F 3/10 - Sintering only
  • B22F 3/11 - Making porous workpieces or articles
  • B29C 64/227 - Driving means
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

90.

Additive manufacturing system having stowable cutting mechanism

      
Application Number 16382054
Grant Number 11052603
Status In Force
Filing Date 2019-04-11
First Publication Date 2019-12-12
Grant Date 2021-07-06
Owner Continuous Composites Inc. (USA)
Inventor
  • Hambling, Colin Hugh
  • Budge, Trevor David
  • Stranberg, Nathan Andrew
  • Overby, Andrew John

Abstract

An additive manufacturing system is disclosed for use in fabricating a composite structure. The additive manufacturing system may include a print head configured to discharge a continuous reinforcement that is at least partially wetted with a matrix, and a support configured to move the print head in at least one dimension during discharge. The additive manufacturing system may also include a cutting mechanism connected to at least one of the print head and the support. The cutting mechanism may be configured to selectively sever the continuous reinforcement from the print head. The cutting mechanism may include a cutting implement, a first actuator configured to move the cutting implement from a stowed position to a deployed position, and a second actuator configured to engage the cutting implement with the continuous reinforcement.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

91.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 16460701
Grant Number 10744708
Status In Force
Filing Date 2019-07-02
First Publication Date 2019-10-24
Grant Date 2020-08-18
Owner Continuous Compostites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

92.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 16460709
Grant Number 10759109
Status In Force
Filing Date 2019-07-02
First Publication Date 2019-10-24
Grant Date 2020-09-01
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

93.

System and print head for continuously manufacturing composite structure

      
Application Number 16279354
Grant Number 11110654
Status In Force
Filing Date 2019-02-19
First Publication Date 2019-10-17
Grant Date 2021-09-07
Owner Continuous Composites Inc. (USA)
Inventor
  • Alvarado, Tyler B.
  • Budge, Trevor David
  • Stockett, Ryan C.

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement. The system may further include an external applicator configured to apply a matrix to the discharged continuous reinforcement, and a cure enhancer configured to expose the matrix to a cure energy at a side of the external applicator opposite the head.

IPC Classes  ?

  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/321 - Feeding
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

94.

System and head for continuously manufacturing composite structure

      
Application Number 16279878
Grant Number 11130284
Status In Force
Filing Date 2019-02-19
First Publication Date 2019-10-17
Grant Date 2021-09-28
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A print head is disclosed for use in an additive manufacturing system. The print head may include a discharge outlet configured to discharge a continuous reinforcement, and an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge. The print head may also include a cure enhancer configured to soften the solid film after discharge.

IPC Classes  ?

  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/321 - Feeding
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

95.

System for continuously manufacturing composite structure

      
Application Number 16279955
Grant Number 11110656
Status In Force
Filing Date 2019-02-19
First Publication Date 2019-10-17
Grant Date 2021-09-07
Owner Continuous Composites Inc. (USA)
Inventor
  • Stuart, Nathaniel Isaak
  • Alvarado, Tyler B.
  • Stockett, Ryan C.

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include at least one support, and a print head operatively connected to the at least one support and configured to discharge composite material. The system may further include an auxiliary tool operatively connected to the at least one support and configured to receive the composite material discharged by the print head.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/218 - Rollers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

96.

System and print head for additive manufacturing system

      
Application Number 16368776
Grant Number 11161300
Status In Force
Filing Date 2019-03-28
First Publication Date 2019-10-17
Grant Date 2021-11-02
Owner Continuous Composites Inc. (USA)
Inventor
  • Budge, Trevor David
  • Stockett, Ryan C.
  • Alvarado, Tyler B.
  • Tyler, Kenneth Lyle
  • Hambling, Colin Hugh
  • Dunham, Brian
  • Stranberg, Nathan Andrew

Abstract

A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a compactor located at the discharging end and forming a tool center point for the print head.

IPC Classes  ?

  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/291 - Arrangements for irradiation for operating globally, e.g. together with selectively applied activators or inhibitors
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 80/00 - Products made by additive manufacturing
  • B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 70/54 - Component parts, details or accessories; Auxiliary operations
  • B32B 38/00 - Ancillary operations in connection with laminating processes
  • B32B 38/18 - Handling of layers or the laminate

97.

SYSTEM AND PRINT HEAD FOR ADDITIVE MANUFACTURING SYSTEM

      
Application Number 16368854
Status Pending
Filing Date 2019-03-29
First Publication Date 2019-10-17
Owner CONTINUOUS COMPOSITES INC. (USA)
Inventor
  • Budge, Trevor David
  • Stockett, Ryan C.
  • Alvarado, Tyler B.
  • Tyler, Kenneth Lyle
  • Hambling, Colin Hugh
  • Dunham, Brian
  • Stranberg, Nathan Andrew

Abstract

A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a feeder located between the receiving end and the discharging end. The feeder may be configured to push the continuous reinforcement out of the print head at only select times during discharge of the continuous reinforcement and the matrix.

IPC Classes  ?

98.

Head and system for continuously manufacturing composite tube

      
Application Number 16455410
Grant Number 10981327
Status In Force
Filing Date 2019-06-27
First Publication Date 2019-10-17
Grant Date 2021-04-20
Owner Continuous Composites inc. (USA)
Inventor
  • Tyler, Kenneth Lyle
  • Beebout, Jeff

Abstract

A method is disclosed for additively manufacturing a composite structure. The method may include coating a continuous strand with a matrix, discharging a composite tubular structure made from the coated continuous strand, and exposing the matrix in the composite tubular structure to light to cure the matrix during discharging. The method may also include depositing a material layer onto an internal surface of the composite tubular structure as the composite tubular structure is being discharged, and wiping a squeegee over the material layer.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 70/52 - Pultrusion, i.e. forming and compressing by continuously pulling through a die
  • B29C 70/50 - Shaping or impregnating by compression for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 48/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C 48/09 - Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
  • B29C 48/21 - Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
  • B29C 48/32 - Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
  • B29C 48/33 - Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles with parts rotatable relative to each other
  • B29C 48/152 - Coating hollow articles the inner surfaces thereof
  • B29C 48/325 - Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles adjustable
  • B29C 48/25 - Component parts, details or accessories; Auxiliary operations
  • B29L 23/00 - Tubular articles
  • B29D 23/00 - Producing tubular articles
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B05B 3/00 - Spraying or sprinkling apparatus with moving outlet elements or moving deflecting elements
  • B05B 3/10 - Spraying or sprinkling apparatus with moving outlet elements or moving deflecting elements with rotating elements discharging over substantially the whole periphery of the rotating member
  • B05B 5/03 - Discharge apparatus, e.g. electrostatic spray guns characterised by the use of gas
  • B05B 5/04 - Discharge apparatus, e.g. electrostatic spray guns characterised by having rotary outlet or deflecting elements
  • B05B 7/14 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
  • B05B 13/06 - Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups specially designed for treating the inside of hollow bodies
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

99.

Method and apparatus for continuous composite three-dimensional printing

      
Application Number 16401541
Grant Number 10744707
Status In Force
Filing Date 2019-05-02
First Publication Date 2019-08-22
Grant Date 2020-08-18
Owner Continuous Composites Inc. (USA)
Inventor Tyler, Kenneth Lyle

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 70/06 - Fibrous reinforcements only
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K 105/16 - Fillers
  • B29K 307/04 - Carbon
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length

100.

Additive manufacturing system implementing hardener pre-impregnation

      
Application Number 15995027
Grant Number 10807303
Status In Force
Filing Date 2018-05-31
First Publication Date 2019-07-18
Grant Date 2020-10-20
Owner Continuous Composites, Inc. (USA)
Inventor
  • Alvarado, Tyler B.
  • Budge, Trevor David
  • Stockett, Ryan C.
  • Swallow, John

Abstract

A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, and coating the continuous reinforcement with a first matrix component inside of the print head. The method may further include coating the continuous reinforcement with a second matrix component, discharging the continuous reinforcement through a nozzle of the print head, and moving the print head in multiple dimensions during the discharging. The first and second matrix components interact to cause hardening of a matrix around the continuous reinforcement.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 31/04 - Feeding, e.g. into a mould cavity
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 70/20 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in a single direction, e.g. roving or other parallel fibres
  • B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 70/24 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
  • B29C 64/295 - Heating elements
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
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