A method and apparatus for forming a 3D article. According to the method, a composite filament material is formed from a UV curable material, a thermoset polymer material and at least one of filaments or fibers. After the composite is formed, the filament is dispensed to form the 3D article. Dispense is typically through a nozzle or other orifice that delivers the composite filament material as a bead of material. As the composite is dispensed, at least a portion of the composite material is exposed to UV radiation thereby curing a portion of the dispensed composite filament. The UV radiation is provided by a light source than can target discrete portions of the dispensed composite filament. For this purpose, the UV radiation source can be a light source integrated with the nozzle or a steered light source. As the composite filament is dispensed, UV radiation is directed onto the composite filament. If a steered light source is used, the composite filament is dispensed and light from the steered UV radiation source is directed to targeted regions of the composite filament, introducing cured zones or regions into the composite filament.
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 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
An apparatus for manufacturing an object includes an extrusion head having an extrusion needle for extruding thermoplastic material associated with one or more fiber strands. The apparatus may further include a turn-table, a more robotic arm for moving the extrusion head and needle, thermoplastic filament and fiber strand spools and thermoplastic filament and fiber strands. A controller is provided for directing the robotic arm, extrusion head and the turn-table. Further, a method for manufacturing an object includes generating a design for the object that substantially satisfies desired structural properties of the object and generating a sequence for extruding one or more beads of thermoplastic material to manufacture the object according to the design, in which the one or more beads of thermoplastic material are associated with one or more fiber strands. The one or more beads of thermoplastic material and the associated one or more fiber strands are then extruded according to the sequence.
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 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
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
3.
Cutter Having Customizable Ideal Mechanical Advantage at Each Point in the Cutting Stroke
A powered shearing mechanism or cutter is disclosed that comprises an asynchronous double class 1 lever and a linear actuator that uses two ganged wheels to pry the effort portion of both levers open and close the jaws. The wheels move linearly—with the distance between them kept constant—and roll along—and exert force against—parts of the levers called “bearing surfaces.” The bearing surfaces are non-planar and reflectively symmetric and their profile is customized to provide any desired ideal mechanical advantage for the cutter. In accordance with the illustrative embodiment, the profile of the bearing surfaces is a circular arc, which provides a bearing surface which is easy to precisely fabricate and that provides a fairly constant ideal mechanical advantage at each point as the cutter's blades cut through the material.
B23D 17/04 - Shearing machines or shearing devices cutting by blades pivoted on a single axis characterised by drives or gearings therefor actuated by a rotary shaft
B23D 17/08 - Shearing machines or shearing devices cutting by blades pivoted on a single axis characterised by drives or gearings therefor actuated by hand or foot operated lever mechanism
B23D 29/00 - Hand-held metal-shearing or metal-cutting devices
B26B 13/06 - Hand shears; Scissors characterised by the shape of the blades
An additive manufacturing system is disclosed that comprises two or more lasers for precisely heating a fiber-reinforced thermoplastic feedstock and a fiber-reinforced thermoplastic workpiece in preparation for depositing and tamping the feedstock onto the workpiece. The system employs feedforward, a variety of sensors, and feedback to ensure that the feedstock and workpiece are properly heated.
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
B23K 26/00 - Working by laser beam, e.g. welding, cutting or boring
B23K 26/03 - Observing, e.g. monitoring, the workpiece
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/08 - Devices involving relative movement between laser beam and workpiece
B23K 26/14 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles 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
An additive manufacturing system is disclosed that comprises two or more lasers for precisely heating a fiber-reinforced thermoplastic feedstock and a fiber-reinforced thermoplastic workpiece in preparation for depositing and tamping the feedstock onto the workpiece. The system employs feedforward, a variety of sensors, and feedback to ensure that the feedstock and workpiece are properly heated.
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
B23K 26/08 - Devices involving relative movement between laser beam and workpiece
B23K 26/067 - Dividing the beam into multiple beams, e.g. multi-focusing
An additive manufacturing system is disclosed that comprises two or more lasers for precisely heating a fiber-reinforced thermoplastic feedstock and a fiber-reinforced thermoplastic workpiece in preparation for depositing and tamping the feedstock onto the workpiece. The system employs feedforward, a variety of sensors, and feedback to ensure that the feedstock and workpiece are properly heated.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B23K 26/00 - Working by laser beam, e.g. welding, cutting or boring
B23K 26/03 - Observing, e.g. monitoring, the workpiece
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/08 - Devices involving relative movement between laser beam and workpiece
B23K 26/14 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
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
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
An additive manufacturing system is disclosed that comprises two or more lasers for precisely heating a fiber-reinforced thermoplastic feedstock and a fiber-reinforced thermoplastic workpiece in preparation for depositing and tamping the feedstock onto the workpiece. The system employs feedforward, a variety of sensors, and feedback to ensure that the feedstock and workpiece are properly heated.
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
B29C 64/141 - Processes of additive manufacturing using only solid materials
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
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
A build plate for 3D printers that facilitates separation of the workpiece from the build plate and yet provides lateral anchoring of the unit cell. The build plate comprises (1) a foundation of a material that the unit cell material will not adhere to or will only weakly adhere to, and (2) a plurality of adhesive islands that provide a lateral anchor for the unit cell. An adhesive island is a hole in the foundation of the build plate that is filled with a plug of material to which the unit cell material will strongly adhere. The number, type, location, and size of the adhesive islands is tailored to provide enough lateral stability where needed, but not more.
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
B29K 71/00 - Use of polyethers as moulding 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 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
9.
Adding a segment of fiber-reinforced thermoplastic filament in a curve
In additive manufacturing, a method of adding a segment of fiber-reinforced thermoplastic filament. Adding a segment of filament involves three tasks: (1) determining where the segment of filament should be added, (2) depositing the segment of filament at the desired location, and (3) tamping the segment of filament to ensure adhesion and eliminate voids. Tamping the segment of filament is performed by steering a wheel along the filament. In accordance with the illustrative embodiment, the wheel is steered around a yaw axis that is offset from the wheel's axis by a distance s, where s is a positive real number.
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 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]
An article of manufacture is disclosed that is formed by jointly controlling a printhead and a worktable to provide three dimensional printing and insuring every point in a three dimensional print volume can be reached. Similarly, systems and methods are described to extend robot reach by coordinating robot and worktable control.
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
The present disclosure provides methods and systems for printing a three-dimensional (3D) object. A model of the 3D object, in computer memory, may be received. Next, at least one filament material from a source may be directed towards a build platform configured to support the 3D object, thereby depositing a first layer of a portion of the 3D object. The at least one filament material may be used to deposit a second layer corresponding to at least a portion of the 3D object. The first and second layers may be deposited in accordance with the model of the 3D object. While, the second layer is being deposited, at least one energy beam may selectively heat a first portion of the first layer and a second portion of the at least one filament material. The first portion may be brought in contact with the second portio-n
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
An article of manufacture is disclosed that includes an infill generated utilizing three dimensional (3D) printing. Infill is generated utilizing segments of filament, such as, but not limited to continuous carbon fiber-reinforced thermoplastic filament. Other materials may also be suitably employed. Approaches to tool path generation which accomplish the 3D printing desired are addressed in which material runs of filament are applied that distribute where cuts, beginning, or ends of segments occur or points where ends of segments are anchored to the article to form the desired infill. Aspects of one approach include first generating a meta tool path for the infill and then adapting that tool path to an actual infill tool path by pruning any segments in the meta tool path extending outside the perimeter of the article and identifying anchor points to the article from observed intersections of the meta tool path and said perimeter.
G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
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]
G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
B33Y 80/00 - Products made by 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
13.
Method and a system to optimize printing parameters in additive manufacturing process
The present invention relates to a system and a method for optimizing printing parameters, such as slicing parameters and tool path instructions, for additive manufacturing. The present invention comprises a property analysis module that predicts and analyses properties of a filament object model, representing a constructed 3D object. The filament object model is generated based on the tool path instructions and user specified object properties. Analysis includes comparing the predicted filament object model properties with the user specified property requirements; and further modifying the printing parameters in order to meet the user specified property requirements.
The present disclosure provides methods for generating a three-dimensional object, comprising directing at least one strand material from a source of at least one strand material towards a base. Next, at least a first light beam and a second light beam from a light source is used to subject at least one strand material to heating at one or more locations along at least one strand material. At least a portion of the three-dimensional object may be generated from at least one strand material upon subjecting at least one strand material to heating along one or more locations.
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]
The present disclosure provides methods for additive manufacturing of a three-dimensional (3D) object, comprising preheating a feed comprising a polymer material to a temperature in excess of a glass transition temperature and below a melting point of the polymer material. The preheating may occur at a first location in an additive manufacturing apparatus. Next, the polymer material may be melted at a second location that is spatially distinct from the first location.
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
B29B 13/02 - Conditioning or physical treatment of the material to be shaped by heating
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
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
B29B 13/08 - Conditioning or physical treatment of the material to be shaped by using wave energy or particle radiation
The present invention provides a system and method for the application of a functional thread to secure roving or other fibers to a substrate, thereby forming a precursor to a resultant composite component structure having targeted, enhanced structural reinforcement. The functional thread may be comprised of one or more fibrous filaments or have a monofilament structure. The invention encompasses the sewing of this functional thread at varying stitch densities as function of component stress analysis, the mechanical stresses that the component will be subject to when exposed to the forces and loads associated with its intended use, and at least one physical or mechanical property of a functional thread. This variable stitch density serves to provide targeted, localized mechanical enhancement and reinforcement to the resultant composite structure.
B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
D05B 3/22 - Article-, e.g. button-, feed mechanisms therefor
D05B 19/14 - Control of needle movement, e.g. varying amplitude or period of needle movement
D05B 19/16 - Control of workpiece movement, e.g. modulation of travel of feed dog
D05B 69/18 - Devices for changing speed or for reversing direction of rotation electric
D05B 19/04 - Sewing machines having electronic memory or microprocessor control unit characterised by memory aspects
An article of manufacture is disclosed that comprises an infill made from linear segments of filament, such as but not limited to continuous carbon fiber-reinforced thermoplastic filament. Feathering approaches are addressed to generate segments of filament in various geometries that distribute where cuts or ends of segments occur or points where two ends of segments are fused or the like to avoid overlap. Aspects of one approach include identifying long edges and eliminating short edges which present acute angles.
An article of manufacture is disclosed that comprises an infill made from linear segments of filament, such as but not limited to continuous carbon fiber-reinforced thermoplastic filament. Approaches to tool path generation are addressed in which material runs of filament are applied that distribute where cuts, beginning, or ends of segments occur or points where two ends of segments are fused or the like to preserve filament continuity by reducing the number of short segments. Aspects of one approach include identifying long edges and eliminating short edges which acute angles with long edges and utilizing a clipping outline as part of the process of determining start and end points of material runs.
B32B 3/10 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of 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
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
The present invention provides a system and a method for real time monitoring and identifying defects occurring in a three dimensional object build via an additive manufacturing process. Further, the present invention provides in-situ correction of such defects by a plurality of functional tool heads possessing freedom of motion in arbitrary planes and approach, where the functional tool heads are automatically and independently controlled based on a feedback analysis from the printing process, implementing analyzing techniques. Furthermore, the present invention provides a mechanism for analyzing defected data collected from detection devices and correcting tool path instructions and object model in-situ during construction of a 3D object. A build report is also generated that displays, in 3D space, the structural geometry and inherent properties of a final build object along with the features of corrected and uncorrected defects. Advantageously, the build report helps in improving 3D printing process for subsequent objects.
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
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
A cutting assembly and a cutter are provided, wherein, in an apparatus for additive manufacturing with a filament, a deposition head has a body and an applicator for fixing a run of filament to a surface at a deposition location ending at a deposition termination point. The cutter assembly has a fixation element for fixing the cutter assembly relative to the deposition head, and a cutter movable relative to the fixation element. The deposition head has a deposition termination configuration and a cutting configuration, and after fixing the run of filament, the deposition head transitions from the deposition termination configuration to the cutting configuration. The cutter cuts the filament only when the deposition head is in the cutting configuration.
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 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
A filament accumulator assembly is provided containing a filament inlet for receiving a continuous filament from the filament source and a filament outlet for receiving the continuous filament from the filament inlet, the continuous filament forming a filament loop between the filament exiting the filament inlet and entering the filament outlet. The filament accumulator assembly further comprises a filament track defining at least part of an inner boundary and an outer boundary of a circuitous filament route between the filament inlet and the filament outlet, and the filament loop is bound by the filament track. The filament loop has a diameter that varies across a range of potential diameters within the filament track.
B65H 59/38 - Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by regulating speed of driving mechanism of unwinding, paying-out, forwarding, winding, or depositing devices, e.g. automatically in response to variations in tension
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
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
22.
Systems and methods for determining tool paths in three-dimensional printing
The present disclosure provides methods and systems for printing a three-dimensional (3D) object. A method for printing a 3D object may comprise receiving a computer model of the 3D object in computer memory and generating a parametric representation of the computer model of the 3D object. Next, a first edge in a parametric representation of a curved surface of the computer model may be selected, and a 3D tool path may be generated at least in part by: (i) selecting a first set of points on the first edge; and (ii) computing coordinates of a second set of points on a second edge parallel to the first edge in the parametric representation, wherein the first edge and the second edge define the 3D tool path. Printing instructions may then be generated for printing at least a portion of the 3D object along the tool path.
The illustrative embodiment of the present invention uses a tangible three-dimensional structure as a fiducial mark, which structure is, at least partially, tolerant of dimensional variations in the article. The illustrative embodiment uses three such tangible three-dimensional structures: (1) a portion of a tangible conical surface, (2) a portion of a tangible spheroidal surface, and (3) a portion of a tangible pyramidal surface.
B23B 35/00 - Methods for boring or drilling, or for working essentially requiring the use of boring or drilling machines; Use of auxiliary equipment in connection with such methods
B23B 39/00 - General-purpose boring or drilling machines or devices; Sets of boring or drilling machines
The illustrative embodiment of the present invention uses a tangible three-dimensional structure as a fiducial mark, which structure is, at least partially, tolerant of dimensional variations in the article. The illustrative embodiment uses three such tangible three-dimensional structures: (1) a portion of a tangible conical surface, (2) a portion of a tangible spheroidal surface, and (3) a portion of a tangible pyramidal surface.
The illustrative embodiment of the present invention uses a tangible three-dimensional structure as a fiducial mark, which structure is, at least partially, tolerant of dimensional variations in the article. The illustrative embodiment uses three such tangible three-dimensional structures: (1) a portion of a tangible conical surface, (2) a portion of a tangible spheroidal surface, and (3) a portion of a tangible pyramidal surface.
The present invention provides a system and method for quickly removing and installing a filament tube and nozzle in an FFF extrusion system. The system utilizes a primary manifold that includes a cooling block, a heating block and a quick-change mechanism. This primary manifold is adapted to mate a filament tube/nozzle assembly. The quick-change mechanism, which in a particular embodiment utilizes a recessed biased-bearing arrangement, enables the filament/nozzle assembly to be removed and inserted without the use of any tools, and without causing any significant downtime for the FFF extrusion system. Once removed, the filament tube/nozzle assembly can be refurbished by a technician, trained so as not to over torque the tube/nozzle threaded interface. This refurbishment (typically consisting of a cleaning and the installation of a new nozzle) could be accomplished “off-line”, without any impact on the continued use of FFF extrusion system.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 48/86 - Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body at a front mounting point or a rear mounting point, or both, and are used to shape the band to a desired contour. The band is made of a flexible material, and has a first and second connecting point, wherein at least one of them is connected to the one or more actuators. The intermediate portion of the band between the connecting points is curved toward the surface of the object being manufactured to enable the portion to come into contact with and to compact the filament onto the object. The band assembly further comprises a compaction support extending from the assembly body toward an inward-facing surface of the band.
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
In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body and are used to shape the band to a desired contour. The band is connected to the one or more actuators, and is capable of being driven along its length by one or more drive wheels. For example, the band can be in the form of a loop, arranged such that the front of the loop is in contact with a front wheel, the back of the loop is in contact a rear wheel, and the bottom of the loop faces toward the surface of the object. The band assembly further comprises a compaction support supporting the band and comprising a roller that permits the band to move along its length.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
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
In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body and are used to shape the band to a desired contour. The band is connected to the one or more actuators, is curved toward the surface of the object to enable contact with the surface, and is capable of being driven along its length by one or more drive wheels that are under the control of a controller. The drive wheels are configured to advance the band along its length by a first distance and in response to a first signal from the controller. The controller provides the first signal based on an estimate of thermoplastic build-up on a portion of the band that overlaps the point of compaction.
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
30.
System and method for dispensing composite filaments for additive manufacturing
A method and apparatus for forming a 3D article. According to the method, a composite filament material is formed from a UV curable material, a thermoset polymer material and at least one of filaments or fibers. After the composite is formed, the filament is dispensed to form the 3D article. Dispense is typically through a nozzle or other orifice that delivers the composite filament material as a bead of material. As the composite is dispensed, at least a portion of the composite material is exposed to UV radiation thereby curing a portion of the dispensed composite filament. The UV radiation is provided by a light source than can target discrete portions of the dispensed composite filament. For this purpose, the UV radiation source can be a light source integrated with the nozzle or a steered light source. As the composite filament is dispensed, UV radiation is directed onto the composite filament. If a steered light source is used, the composite filament is dispensed and light from the steered UV radiation source is directed to targeted regions of the composite filament, introducing cured zones or regions into the composite filament.
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 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
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
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
The present invention provides an integral cooling system within an FFF nozzle manifold. The system includes a cooling reservoir formed within the body of the nozzle manifold, adapted to circulate a cooling liquid around the filament chamber and nozzle orifice. The coolant channel is situated to be in close physical proximity to the chamber and orifice, and to be thermally coupled to both via the body of the nozzle manifold. In addition, the interior of the cooling chamber is constructed so as to maximize the available surface area within a given cross-sectional geometry, thereby promoting increase heat transfer between the nozzle manifold and the cooling liquid.
F28D 15/00 - Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls
F28F 7/02 - Blocks traversed by passages for heat-exchange media
F28D 7/00 - Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
B33Y 80/00 - Products made by additive manufacturing
B33Y 70/00 - Materials specially adapted for additive manufacturing
An article of manufacture is disclosed that comprises an infill made from linear segments of filament, such as but not limited to continuous carbon fiber-reinforced thermoplastic filament. Embodiments of the present invention comprises segments of filament in various geometries that distribute where adjacent segments overlap and are fused and where segments do not overlap. Embodiments of the present invention include quadrilateral (e.g., orthogonal, rectangular, etc.) infill and hexagonal (e.g., regular hexagonal, irregular hexagonal, convex hexagonal, etc.) infill.
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 80/00 - Products made by 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
The illustrative embodiment comprises the sewing of fibers into a sewing substrate, which is then overmolded, to enable the manufacture of strong and lightweight articles with complex geometries.
B29C 70/16 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
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 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 70/88 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
D05B 1/14 - Combined or alternative chain-stitch and lock-stitch seams
A technique for additive manufacturing that avoids the necessity of having a build plate. The illustrative embodiment comprises two anchor plates from which a structure is constructed that forms at least the initial support for the object to be manufactured. The envelope of the structure can be a cylinder, a box, an n-sided prism, a hyperboloid of one sheet, a cone, the frustum of a cone, a pyramid, and the frustum of a pyramid.
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
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
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A technique for depositing fiber-reinforced thermoplastic filament in an arc is disclosed that mitigates the centripetal forces that arise in the prior art. In accordance with the illustrative embodiment, the centripetal forces are ameliorated by twisting the filament while depositing it in an arc.
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 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
A consumable scaffold and technique for supporting an object while it is being manufactured is disclosed. The consumable scaffold comprises a base sheet and an array of pillars that are cantilevered from one side of the sheet. The consumable scaffold resembles a bed of nails. Each pillar in the array of pillars is trimmed to a desired length and the object is manufactured by fusing thermoplastic filaments to the tips of the pillars.
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
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 40/00 - Auxiliary operations or equipment, e.g. for material handling
B33Y 80/00 - Products made by 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
A nozzle for dispense of a material that is a composite of fillers such as short fibers (e.g. carbon fibers) and a polymer matrix. The nozzle through which the composite material is dispensed has an expansion region through which the composite material flows. The expansion region dispenses a composite material wherein the fibers are substantially not aligned (e.g. in a random orientation with respect to each other in the polymer matrix).
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
B33Y 70/00 - Materials specially adapted for additive manufacturing
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
A filament guide that guides thermoplastic filament to an object being manufactured. A deposition head comprising the disclosed filament guide provides a filament to the intended deposition point. The filament guide comprises a guide member having a filament groove configured to guide the filament along a path of travel. The groove has an upstream end that is configured to receive the filament from a source and a downstream end that is configured to direct the filament toward the deposition point in the intended direction. A notch at the downstream end of the guide member enables the filament to travel toward the deposition point. The portions of the guide member on either side of the notch act to keep the filament centered laterally. A plate that is transparent to electromagnetic radiation from a heat source covers the groove and permits the electromagnetic radiation to reach the filament while providing added support.
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
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]
A filament inspection system is disclosed that gathers empirical data on the physical and chemical properties of filament. The illustrative embodiments need only a single video camera and two mirrors to image all of the exterior surfaces of one or more filaments simultaneously. These images can be used to analyze the physical properties of the filament. Furthermore, the illustrative embodiments need only a simple electrical network to gather empirical data on the permittivity of each segment of filament, which gives insights into the chemical properties of the filament. For example, embodiments of the present invention are particularly well suited for inspecting fiber-reinforced thermoplastic filament, and variations in the number, dispersion, wetting, and length of the fibers are all observable in variations in permittivity.
G01N 27/22 - Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating capacitance
G01B 11/24 - Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
40.
Fiducial marks for articles of manufacture with non-trivial dimensional variations
The illustrative embodiment of the present invention uses a tangible three-dimensional structure as a fiducial mark, which structure is, at least partially, tolerant of dimensional variations in the article. The illustrative embodiment uses three such tangible three-dimensional structures: (1) a portion of a tangible conical surface, (2) a portion of a tangible spheroidal surface, and (3) a portion of a tangible pyramidal surface.
An apparatus and method for managing bending and other applied forces that are exerted on a filament of thermoplastic with reinforcing fibers in a 3D printing system during the deposition process that is associated with the manufacturing of an object. The quality of the manufactured object is enhanced through a process that comprises i) applying torque to certain portions of the solid filament in a manner that is commensurate with the expected motions of the deposition head while depositing those portions, but only after ii) heating each portion to a sufficient temperature. A heating device and a twisting device act on the filament while it is moving toward the deposition point and while under the control of a controller that is operating according to a computer model of the object being manufactured.
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 70/00 - Materials specially adapted for additive manufacturing
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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]
42.
Systems for additive manufacturing using feedstock shaping
A method and apparatus for additive manufacturing wherein a fiber composite filament having an arbitrarily shaped cross section is softened and then flattened to tape-like form factor for incorporation into a part that is being additively manufactured.
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
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 64/20 - 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
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 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
An apparatus for manufacturing an object includes an extrusion head having an extrusion needle for extruding thermoplastic material associated with one or more fiber strands. The apparatus may further include a turn-table, a more robotic arm for moving the extrusion head and needle, thermoplastic filament and fiber strand spools and thermoplastic filament and fiber strands. A controller is provided for directing the robotic arm, extrusion head and the turn-table. Further, a method for manufacturing an object includes generating a design for the object that substantially satisfies desired structural properties of the object and generating a sequence for extruding one or more beads of thermoplastic material to manufacture the object according to the design, in which the one or more beads of thermoplastic material are associated with one or more fiber strands. The one or more beads of thermoplastic material and the associated one or more fiber strands are then extruded according to the sequence.
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 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
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
The present disclosure provides methods and systems for printing a three-dimensional (3D) object. A method for printing a 3D object may comprise receiving a computer model of the 3D object in computer memory and generating a parametric representation of the computer model of the 3D object. Next, a first edge in a parametric representation of a curved surface of the computer model may be selected, and a 3D tool path may be generated at least in part by: (i) selecting a first set of points on the first edge; and (ii) computing coordinates of a second set of points on a second edge parallel to the first edge in the parametric representation, wherein the first edge and the second edge define the 3D tool path. Printing instructions may then be generated for printing at least a portion of the 3D object along the tool path.
A process of additive manufacturing in which a stack of non-planar layers of material are deposited for manufacturing an object. The non-planar layers can conform to the surface of the object or not. The non-planar layers can create structurally-advantageous interior structures in the object. The contours of the non-planar layers can be different or can be the same.
B33Y 50/00 - Data acquisition or data processing for 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]
46.
Duct fabricated with additive manufacturing from a run of material in the form of one or more spirals
Ducts manufactured by depositing one or more runs of material in a helix, a plurality of conjoined planar spirals, and a conjoined plurality of conical spirals.
F16L 9/12 - Rigid pipes of plastics with or without reinforcement
B33Y 80/00 - Products made by additive manufacturing
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 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
B29C 64/386 - Data acquisition or data processing for additive manufacturing
Methods for producing 3D printing composite polymer materials for use in additive manufacturing processes are provided. The methods result in enhancing the material properties of the printing material by providing a uniform and smooth surface finish of the printing material and the nozzle extrudate for additive manufacturing processes, such as Fused Filament Fabrication. The method includes implementing impregnation techniques for combining carbon nanotubes or other nano-fillers, a polymer resin and a fiber material to produce a polymer material that can be processed into a printing material. Further, the method may include combining the carbon nanotubes or other nano-fillers and the polymer resin to form a masterbatch that may be further combined with the fiber material through an extrusion process. The method results in a printing material with enhanced material properties and smooth surface finish for the printing material and resulting nozzle extrudate for Fused Filament Fabrication.
A system and method for additive manufacturing of otherwise thermosetting polymers, such as PAI, is disclosed. The system includes fast-curing hardware that facilitates curing each deposited layer before a successive layer is deposited. This reduces the time to provide a finished part from weeks to hours.
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]
49.
Method and Apparatus for Additive Manufacturing with Preheat
A polymeric material used for 3D printing is preheated, at a first zone in a 3D printer, to a temperature in excess of its glass transition temperature prior to being melted, at a second zone, for incorporation into a build object. This enables the polymer to be processed more rapidly than in the prior art.
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
50.
Duct fabricated with additive manufacturing and having one or more curves
Curvilinear ducts manufactured by depositing one or more runs of material in a conjoined helix, a conjoined plurality of conjoined planar spirals, and a plurality of conjoined conical spirals.
B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
B29C 64/386 - Data acquisition or data processing for additive manufacturing
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
A filament guide that guides thermoplastic filament to an object being manufactured. A deposition head comprising the disclosed filament guide provides a filament to the intended deposition point. The filament guide comprises a guide member having a filament groove configured to guide the filament along a path of travel. The groove has an upstream end that is configured to receive the filament from a source and a downstream end that is configured to direct the filament toward the deposition point in the intended direction. A notch at the downstream end of the guide member enables the filament to travel toward the deposition point. The portions of the guide member on either side of the notch act to keep the filament centered laterally. A plate that is transparent to electromagnetic radiation from a heat source covers the groove and permits the electromagnetic radiation to reach the filament while providing added support.
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
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
Ducts manufactured by depositing one or more runs of material in a helix, a plurality of conjoined planar spirals, and a conjoined plurality of conical spirals.
An apparatus and method for managing bending and other applied forces that are exerted on a filament of thermoplastic with reinforcing fibers in a 3D printing system during the deposition process that is associated with the manufacturing of an object. The quality of the manufactured object is enhanced through a process that comprises i) applying torque to certain portions of the solid filament in a manner that is commensurate with the expected motions of the deposition head while depositing those portions, but only after ii) heating each portion to a sufficient temperature. A heating device and a twisting device act on the filament while it is moving toward the deposition point and while under the control of a controller that is operating according to a computer model of the object being manufactured.
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 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 70/00 - Materials specially adapted for additive manufacturing
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
54.
Curvilinear duct fabricated with additive manufacturing
Curvilinear ducts manufactured by depositing one or more runs of material in a conjoined helix, a conjoined plurality of conjoined planar spirals, and a plurality of conjoined conical spirals.
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
55.
Method and a system to optimize printing parameters in additive manufacturing process
The present invention relates to a system and a method for optimizing printing parameters, such as slicing parameters and tool path instructions, for additive manufacturing. The present invention comprises a property analysis module that predicts and analyses properties of a filament object model, representing a constructed 3D object. The filament object model is generated based on the tool path instructions and user specified object properties. Analysis includes comparing the predicted filament object model properties with the user specified property requirements; and further modifying the printing parameters in order to meet the user specified property requirements.
G06F 19/00 - Digital computing or data processing equipment or methods, specially adapted for specific applications (specially adapted for specific functions G06F 17/00;data processing systems or methods specially adapted for administrative, commercial, financial, managerial, supervisory or forecasting purposes G06Q;healthcare informatics G16H)
B29C 64/386 - Data acquisition or data processing for additive manufacturing
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
56.
Method to manufacture polymer composite materials with nano-fillers for use in additive manufacturing to improve material properties
Methods for producing 3D printing composite polymer materials for use in additive manufacturing processes are provided. The methods result in enhancing the material properties of the printing material by providing a uniform and smooth surface finish of the printing material and the nozzle extrudate for additive manufacturing processes, such as Fused Filament Fabrication. The method includes implementing impregnation techniques for combining carbon nanotubes or other nano-fillers, a polymer resin and a fiber material to produce a polymer material that can be processed into a printing material. Further, the method may include combining the carbon nanotubes or other nano-fillers and the polymer resin to form a masterbatch that may be further combined with the fiber material through an extrusion process. The method results in a printing material with enhanced material properties and smooth surface finish for the printing material and resulting nozzle extrudate for Fused Filament Fabrication.
The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.
B29C 67/00 - Shaping techniques not covered by groups , or
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
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 64/118 - 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 64/268 - Arrangements for irradiation using electron beams [EB]
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/067 - Dividing the beam into multiple beams, e.g. multi-focusing
B23K 26/34 - Laser welding for purposes other than joining
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
58.
Localized heating to improve interlayer bonding in 3D printing
The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.
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 64/135 - 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
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 67/00 - Shaping techniques not covered by groups , or
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 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/067 - Dividing the beam into multiple beams, e.g. multi-focusing
B23K 26/34 - Laser welding for purposes other than joining
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
59.
Localized heating to improve interlayer bonding in 3D printing
The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.
B29C 67/00 - Shaping techniques not covered by groups , or
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
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 64/118 - 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 64/268 - Arrangements for irradiation using electron beams [EB]
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/067 - Dividing the beam into multiple beams, e.g. multi-focusing
B23K 26/34 - Laser welding for purposes other than joining
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
60.
Localized heating to improve interlayer bonding in 3D printing
The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.
B29C 67/00 - Shaping techniques not covered by groups , or
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
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 64/118 - 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 64/268 - Arrangements for irradiation using electron beams [EB]
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/067 - Dividing the beam into multiple beams, e.g. multi-focusing
B23K 26/34 - Laser welding for purposes other than joining
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
61.
Systems and methods for structurally analyzing and printing parts
Methods and systems are disclosed for structurally analyzing and/or three-dimensional printing a part. The method may comprise receiving a model of the part for three-dimensional printing from a material comprising a matrix, receiving one or more properties for the material, and using the model, determining a print head tool path for use during the three-dimensional printing of the part. The method may also comprise determining a trajectory of at least one stiffness-contributing portion of the material based at least in part on the print head tool path, determining a performance of the part based at least in part on the one or more properties and the trajectory, and electronically outputting the performance of the part.
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
B29C 64/386 - Data acquisition or data processing for 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]
62.
Method for additive manufacturing using filament shaping
A method and apparatus for additive manufacturing wherein a fiber composite filament having an arbitrarily shaped cross section is softened and then flattened to tape-like form factor for incorporation into a part that is being additively manufactured.
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 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
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
Methods and systems are disclosed for structurally analyzing and/or three-dimensional printing a part. The method may comprise receiving a model of the part for three-dimensional printing from a material comprising a matrix, receiving one or more properties for the material, and using the model, determining a print head tool path for use during the three-dimensional printing of the part. The method may also comprise determining a trajectory of at least one stiffness-contributing portion of the material based at least in part on the print head tool path, determining a performance of the part based at least in part on the one or more properties and the trajectory, and electronically outputting the performance of the part.
A material for use in a fused filament fabrication (FFF) printer comprises a polyaryletherketone (PAEK) having an amorphous morphology. In some embodiments, the material also includes a PAEK having a semi-crystalline morphology.
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
C08L 71/00 - Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
C08L 71/10 - Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
An apparatus for manufacturing an object includes an extrusion head having an extrusion needle for extruding thermoplastic material associated with one or more fiber strands. The apparatus may further include a turn-table, a more robotic arm for moving the extrusion head and needle, thermoplastic filament and fiber strand spools and thermoplastic filament and fiber strands. A controller is provided for directing the robotic arm, extrusion head and the turn-table. Further, a method for manufacturing an object includes generating a design for the object that substantially satisfies desired structural properties of the object and generating a sequence for extruding one or more beads of thermoplastic material to manufacture the object according to the design, in which the one or more beads of thermoplastic material are associated with one or more fiber strands. The one or more beads of thermoplastic material and the associated one or more fiber strands are then extruded according to the sequence.
B29C 67/00 - Shaping techniques not covered by groups , or
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 64/20 - 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 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
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
An apparatus and method for printing an object via additive manufacturing is disclosed. In accordance with an illustrative embodiment, one or more inks are prepared, including a thermo-polymer ink, a nano-filler ink, and a thermo-polymer/nano-filler ink. In some embodiments, an object is printed by depositing alternating layers of thermo-polymer ink and nano-filler ink and exposing the layers to microwave radiation. In some other embodiments, an object is printed by depositing alternating layers of thermo-polymer/nano-filler ink and nano-filler ink and exposing the layers to microwave radiation. In some additional embodiments, an object is printed by depositing successive layers of thermo-polymer/nano-filler ink and exposing them to microwave radiation.
B29C 67/00 - Shaping techniques not covered by groups , or
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 70/00 - Materials specially adapted for additive manufacturing
C08K 7/24 - Expanded, porous or hollow particles inorganic
C09D 11/037 - Printing inks characterised by features other than the chemical nature of the binder characterised by the pigment
C09D 11/102 - Printing inks based on artificial resins containing macromolecular compounds obtained by reactions other than those only involving unsaturated carbon-to-carbon bonds
C09D 11/324 - Pigment inks containing carbon black
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
B29K 71/00 - Use of polyethers as moulding material
Methods for producing 3D printing composite polymer materials for use in additive manufacturing processes are provided. The methods result in enhancing the material properties of the printing material by providing a uniform and smooth surface finish of the printing material and the nozzle extrudate for additive manufacturing processes, such as Fused Filament Fabrication. The method includes implementing impregnation techniques for combining carbon nanotubes or other nano-fillers, a polymer resin and a fiber material to produce a polymer material that can be processed into a printing material. Further, the method may include combining the carbon nanotubes or other nano-fillers and the polymer resin to form a masterbatch that may be further combined with the fiber material through an extrusion process. The method results in a printing material with enhanced material properties and smooth surface finish for the printing material and resulting nozzle extrudate for Fused Filament Fabrication.
A system and method for additive manufacturing of otherwise thermosetting polymers, such as PAI, is disclosed. The system includes fast-curing hardware that facilitates curing each deposited layer before a successive layer is deposited. This reduces the time to provide a finished part from weeks to hours.
The present invention provides a system and a method for real time monitoring and identifying defects occurring in a three dimensional object build via an additive manufacturing process. Further, the present invention provides in-situ correction of such defects by a plurality of functional tool heads possessing freedom of motion in arbitrary planes and approach, where the functional tool heads are automatically and independently controlled based on a feedback analysis from the printing process, implementing analyzing techniques. Furthermore, the present invention provides a mechanism for analyzing defected data collected from detection devices and correcting tool path instructions and object model in-situ during construction of a 3D object. A build report is also generated that displays, in 3D space, the structural geometry and inherent properties of a final build object along with the features of corrected and uncorrected defects. Advantageously, the build report helps in improving 3D printing process for subsequent objects.
The present invention relates to a system and a method for optimizing printing parameters, such as slicing parameters and tool path instructions, for additive manufacturing. The present invention comprises a property analysis module that predicts and analyses properties of a filament object model, representing a constructed 3D object. The filament object model is generated based on the tool path instructions and user specified object properties. Analysis includes comparing the predicted filament object model properties with the user specified property requirements; and further modifying the printing parameters in order to meet the user specified property requirements.
G06F 19/00 - Digital computing or data processing equipment or methods, specially adapted for specific applications (specially adapted for specific functions G06F 17/00;data processing systems or methods specially adapted for administrative, commercial, financial, managerial, supervisory or forecasting purposes G06Q;healthcare informatics G16H)
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B29C 67/00 - Shaping techniques not covered by groups , or
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
71.
Heated build platform and system for three dimensional printing methods
An apparatus performing as a base for printing 3D objects using high temperature thermoplastics employing additive manufacturing methods is provided. The apparatus comprises a heated build platform, a thin removable plate secured on top of the build platform, a high temperature polymer coating applied over the removable plate, and surface treatment of high temperature polymer coating to maintain adhesion between 3D object and printing surface. Also, the removable plate has low coefficient of thermal expansion compared to build platform below it, for avoiding bowing of the plate as it is heated due to heated build platform, hence providing flat printing surface. The thin removable plate allows 3D objects to pop off the plate upon cooling, without damaging the polymer coating, the plate, or the object. It also allows for continuous operation of printing, while the plate is released for cooling, a new plate is installed for printing.
B29C 67/00 - Shaping techniques not covered by groups , or
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
patents
