Additive manufacturing system having fiber-cutting mechanism

• US 10,040,240 B1
• Filed: 06/15/2017
• Issued: 08/07/2018
• Est. Priority Date: 01/24/2017
• Status: Expired due to Fees

• Current Assignee: Continuous Composites Inc.
• Original Assignee: CC3D LLC
• Inventors: Tyler, Kenneth Lyle, Budge, Trevor David, Beebout, Jeff
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Cummins, IV, Manley L
• Application Number:
  US15/623,881
• Publication Number:
  US 20180207868A1
• Time in Patent Office: 418 Days
• Field of Search: None
• CPC Class Codes: B23K 2101/38 Conductors
• CPC Class Codes: B23K 2103/38 Fabrics, fibrous materials
• CPC Class Codes: B23K 26/0876 in at least two axial directions
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B23K 26/402 involving non-metallic material, e.g. isolators
• CPC Class Codes: B23K 37/0235 the guide member forming part of a portal
• CPC Class Codes: B26D 7/086 by vibrating, e.g. ultrasonically
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/227 Driving means
• CPC Class Codes: B29C 64/232 for motion along the axis orthogonal to the plane of a layer
• CPC Class Codes: B29C 64/268 using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include a head having a nozzle configured to discharge a composite material, including a matrix and a continuous reinforcement. The system may also include a cure enhancer configured to enhance curing of the matrix, and a support configured to move the head during discharging to create a structure having a three-dimensional trajectory. The system may further include a cutting mechanism operatively mounted to at least one of the head and the support, and configured to sever the continuous reinforcement after discharge from the nozzle. The cutting mechanism may include a blade, and an ultrasonic energy source connected to the blade.

Claims

1. An additive manufacturing system, comprising:

a head having a nozzle configured to discharge a composite material including a matrix and a continuous reinforcement;

a cure enhancer configured to enhance curing of the matrix;

a support configured to move the head during discharging to create a structure having a three-dimensional trajectory; and

a cutting mechanism operatively mounted to at least one of the head and the support and configured to sever the continuous reinforcement after discharge from the nozzle, the cutting mechanism including a blade and an ultrasonic energy source connected to the blade, wherein;

the blade is located at a tip end of an arm;

an actuator is configured to actuate in an axial direction of the nozzle to move the blade radially inward toward the continuous reinforcement; and

the blade is deformed radially inward by actuation of the actuator.

2. The additive manufacturing system of claim 1, wherein:

the arm is one of an outer set of arms configured to sever the continuous reinforcement; and

the cutting mechanism further includes an inner set of arms configured to grasp the continuous reinforcement.

3. The additive manufacturing system of claim 2, wherein:

the actuator is a first actuator associated with the outer set of arms; and

the cutting mechanism further includes a second actuator associated with the inner set of arms.

4. The additive manufacturing system of claim 3, wherein ends of the inner set of arms are at least one of blunted, elastomeric, and roughened.

5. An additive manufacturing system, comprising:

a head having a nozzle configured to discharge a composite material including a matrix and a continuous reinforcement;

a cure enhancer configured to enhance curing of the matrix;

a support configured to move the head during discharging to create a structure having a three-dimensional trajectory; and

a cutting mechanism configured to sever the continuous reinforcement after discharge from the nozzle, the cutting mechanism including;

an arm having a cutting end; and

an actuator connected to the head and configured to deform the arm radially inward to engage the continuous reinforcement.

6. The additive manufacturing system of claim 5, wherein:

the arm is one of an outer set of arms configured to sever the continuous reinforcement; and

the cutting mechanism further includes an inner set of arms configured to grasp the continuous reinforcement.

7. The additive manufacturing system of claim 6, wherein:

ends of the inner set of arms are at least one of blunted, elastomeric, and roughened; and

ends of the outer set of arms are at least one of hardened and sharpened.