Methods and apparatus for mobile additive manufacturing

• US 10,201,932 B2
• Filed: 04/26/2018
• Issued: 02/12/2019
• Est. Priority Date: 06/23/2013
• Status: Active Grant

• Current Assignee: Frederick A. Flitsch, Robert A. Flitsch
• Original Assignee: Frederick A. Flitsch, Robert A. Flitsch
• Inventors: Flitsch, Robert A., Flitsch, Frederick A.
• Primary Examiner(s): Sultana, Nahida
• Application Number:
  US15/963,767
• Publication Number:
  US 20180243992A1
• Time in Patent Office: 292 Days
• CPC Class Codes: B22F 10/30 Process control
• CPC Class Codes: B22F 10/80 Data acquisition or data processing
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/227 Driving means
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29L 2031/776 Walls, e.g. building panels
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• 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
• CPC Class Codes: E01C 11/005 Methods or materials for repairing pavings E01C7/35 takes precedence; for concrete coverings E01C7/147; for bituminous coverings E01C7/187; devices for repair works E01C23/06; repairing bridge floorings E01D22/00
• CPC Class Codes: E01C 23/01 Devices or auxiliary means for setting-out or checking the configuration of new surfacing, e.g. templates, screed or reference line supports form rails E01C19/50; Applications of apparatus for measuring, indicating, or recording the surface configuration of existing surfacing, e.g. profilographs E01C23/07 takes precedence; measuring roughness or irregularity in general G01B
• CPC Class Codes: E01C 23/06 Devices or arrangements for working the finished surface working freshly laid paving E01C19/42 - E01C19/44, E01C23/02; mining picks E21C35/18; Devices for repairing or reconditioning the surface of damaged paving; Recycling in place or on the road
• CPC Class Codes: E01C 23/065 Recycling in place or on the road, i.e. hot or cold reprocessing of paving in situ or on the traffic surface, with or without adding virgin material or lifting of salvaged material; Repairs or resurfacing involving at least partial reprocessing of the existing paving in situ mixing of hydraulic cement concrete E01C19/025; apparatus for in-plant recycling E01C19/1004, E01C19/1036
• CPC Class Codes: E01C 23/07 Apparatus combining measurement of the surface configuration of paving with application of material in proportion to the measured irregularities measuring means only E01C23/01 G01B
• CPC Class Codes: E01C 23/0966 for filling or priming, with or without working the surface of the filling or applying particulate material thereto, e.g. for filling the joints of stone-sett paving E01C23/096, E01C23/0993 take precedence
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The present disclosure provides various aspects for mobile and automated processing utilizing additive manufacturing. The present disclosure includes methods for the utilization of mobile and automated processing apparatus. In some examples, the mobile additive manufacturing apparatus may perform surface treatments that alter the topography of an existing surface. Other examples may involve the processing of dimensionally large layers which may be joined together to create large pieces with three dimensional shape.

Claims

1. A mobile additive manufacturing apparatus comprising:

a controller capable of executing algorithms and providing control signals;

an additive manufacturing system to deposit a material or combination of materials in prescribed locations across a surface according to a first digital model processed by the controller;

a drive system operative to transport the additive manufacturing system along the surface;

a vision system capable of scanning the surface and measuring a topography of the surface;

a navigation system to determine a location of the additive manufacturing system and guide the drive system;

a power system capable of providing power to operate at least the drive system, navigation system, control system and additive manufacturing system a second digital model formed by measurement utilizing the vision system, wherein the second digital model is of a topography of the surface and defects in a region proximate to the mobile additive manufacturing apparatus;

a material storage system capable to store at least a first material to be supplied to the additive manufacturing system, wherein the material storage system maintains storage conditions by controlling one or more of temperature and pressure;

a surface preparation system capable to remove one or more of flaked surface material, dust, dirt and debris from the surface in advance of the additive manufacturing system; and

a communication system capable of transmitting signals outside the mobile additive manufacturing apparatus and receiving signals originating from outside the mobile additive manufacturing apparatus, wherein the transmitted signals comprise one or more of radiofrequency, infrared, optical or sound based emissions.

2. The apparatus of claim 1 wherein:

the additive manufacturing system comprises a three dimensional printing head.

3. The apparatus of claim 2 wherein:

the additive manufacturing system comprises an array of nozzles which individually eject droplets in response to an electronic control signal provided to the nozzles.

4. The apparatus of claim 3 wherein the droplets comprise one or more of water, an aqueous solution, a hydrocarbon based solvent or an emulsion comprising water or hydrocarbon based solvent.

5. A method for treating a surface comprising:

transmitting a control signal to an apparatus wherein the apparatus comprises;

a controller capable of executing algorithms and providing control signals,

an additive manufacturing system to deposit a material or combination of materials in prescribed locations on the surface according to a first digital model processed by the controller,

a vision system capable of scanning the surface and measuring a topography of the surface,

a drive system operative to transport the additive manufacturing system along the surface,

a navigation system to determine a location of the additive manufacturing system and guide the drive system, and

power system capable of providing power to operate at least the drive system, navigation system, control system and additive manufacturing system;

performing a metrology process to measure a topography of a region of the surface and

locating defects of the region of the surface with the measured topography;

depositing a first layer of the material or combination of materials on the surface utilizing the apparatus;

moving the apparatus to a different location; and

depositing a second layer of the material or combination of materials on the different location of the surface.

6. The method of claim 5 additionally comprising:

processing with an algorithmic processor a result of the metrology process; and

controlling the additive manufacturing system based on the algorithmic processing.

7. A method for forming and repairing a roadway comprising:

transmitting a control signal to an apparatus, wherein the apparatus is a mobile additive manufacturing apparatus comprising;

a controller capable of executing algorithms and providing control signals,

an additive manufacturing system to deposit a material or combination of materials in prescribed locations across a surface of the roadway according to a first digital model processed by the controller,

a vision system capable of scanning the surface and measuring a topography of the surface,

a drive system operative to transport the additive manufacturing system along the surface,

a navigation system to determine a location of the additive manufacturing system and guide the drive system, and

power system capable of providing power to operate at least the drive system, navigation system, control system and additive manufacturing system;

performing a metrology process to measure a topography of a region of the surface;

locating defects of the region of the surface with the measured topography;

forming a first deposit of a first material on the surface;

moving the apparatus to a different location; and

forming a second deposit of a second material on the different location.

8. The method of claim 7 wherein the second material is conductive.

9. The method of claim 8 wherein a channel is formed within the deposit.

10. The method of claim 9 wherein a wire or fiber is located within the channel.

11. The method of claim 10 additionally comprising:

adding a roadway bed upon the surface and the first deposit; and

transporting an internet connected signal through the wire or fiber.