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System and method for forming three-dimensional structures

  • US 10,391,705 B2
  • Filed: 05/09/2014
  • Issued: 08/27/2019
  • Est. Priority Date: 05/09/2014
  • Status: Active Grant
First Claim
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1. A method of manufacturing a structure onto a base component, comprising:

  • providing a nozzle in a first position near the base component, the nozzle being configured to extrude material in a first direction perpendicular to the base component;

    extruding a first portion of material in a continuous flow through the nozzle in the first direction onto the base component, wherein the first portion of material spreads radially outwardly in a second direction that is perpendicular to the first direction when the first portion of material contacts the base component;

    forming a first portion of the structure including the extruded first portion of material;

    moving the nozzle away from the first portion of material in a third direction that is opposite the first direction to a second position;

    extruding a second portion of material in a continuous flow through the nozzle in the first direction onto the first portion of the structure, wherein the second portion of material spreads radially outwardly in the second direction when the second portion of material contacts the first portion of the structure;

    forming a second portion of the structure including the extruded second portion of material;

    wherein the first portion of the structure has a first cross-sectional area perpendicular to the first direction and the second portion of the structure has a second cross-sectional area perpendicular to the first direction; and

    wherein the first cross-sectional area is different from the second cross-sectional area;

    further comprising varying a rate at which the nozzle is withdrawn from the base component during material extrusion to control a radial outflow rate of extruded material and thereby control the first cross-sectional area and the second cross sectional area, wherein the first cross-sectional area of the first portion of the structure corresponds to a first withdrawal rate of the nozzle and wherein the second cross-sectional area of the second portion of the structure corresponds to a second withdrawal rate of the nozzle that is different from the first withdrawal rate.

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