Systems and methods for additively manufacturing composite parts
First Claim
1. A system for additively manufacturing a composite part, the system comprising:
- a feedstock source comprising a plurality of pre-consolidated tows, wherein each pre-consolidated tow comprises a fiber tow within a non-liquid binding matrix;
a tow combiner positioned to receive at least a subset of the plurality of pre-consolidated tows from the feedstock source, and wherein the tow combiner is configured to combine the subset of the plurality of pre-consolidated tows to define a macro tow, wherein the tow combiner is configured to selectively and actively alter a shape of a cross-sectional profile of the macro tow along a length of the macro tow as the subset of the plurality of pre-consolidated tows is being combined to create the macro tow; and
a feed mechanism configured to selectively start and stop movement of a selection of the plurality of pre-consolidated tows from the feedstock source and into the tow combiner to actively alter the shape of the cross-sectional profile of the macro tow along the length of the macro tow as the macro tow is being created, and wherein the feed mechanism is further configured to move the macro tow from the tow combiner.
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Abstract
Systems and methods for additively manufacturing composite parts are disclosed. Systems comprise at least a feedstock source and a feed mechanism. The feedstock source comprises a plurality of pre-consolidated tows, with each pre-consolidated tow comprising a fiber tow within a non-liquid binding matrix. In some systems, a tow combiner receives at least a subset of the plurality of pre-consolidated tows from the feedstock source and combines the subset of the plurality of pre-consolidated tows to define a macro tow. The feed mechanism moves the subset of the plurality of pre-consolidated tows from the feedstock source and into the tow combiner and moves the macro tow from the tow combiner. Methods according to the present disclosure comprise combining a plurality of pre-consolidated tows to define a macro tow, and dispensing the macro tow in three dimensions to define a composite part.
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Citations
21 Claims
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1. A system for additively manufacturing a composite part, the system comprising:
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a feedstock source comprising a plurality of pre-consolidated tows, wherein each pre-consolidated tow comprises a fiber tow within a non-liquid binding matrix; a tow combiner positioned to receive at least a subset of the plurality of pre-consolidated tows from the feedstock source, and wherein the tow combiner is configured to combine the subset of the plurality of pre-consolidated tows to define a macro tow, wherein the tow combiner is configured to selectively and actively alter a shape of a cross-sectional profile of the macro tow along a length of the macro tow as the subset of the plurality of pre-consolidated tows is being combined to create the macro tow; and a feed mechanism configured to selectively start and stop movement of a selection of the plurality of pre-consolidated tows from the feedstock source and into the tow combiner to actively alter the shape of the cross-sectional profile of the macro tow along the length of the macro tow as the macro tow is being created, and wherein the feed mechanism is further configured to move the macro tow from the tow combiner. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 21)
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18. A system for additively manufacturing a composite part, the system comprising:
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a feedstock source comprising a plurality of pre-consolidated tows, wherein each pre-consolidated tow comprises a fiber tow within a non-liquid binding matrix; a tow combiner positioned to receive at least a subset of the plurality of pre-consolidated tows from the feedstock source, wherein the tow combiner is configured to combine the subset of the plurality of pre-consolidated tows to define a macro tow, wherein the tow combiner comprises a plurality of inlets with each inlet of at least a first subset of the plurality of inlets configured to receive an individual pre-consolidated tow of the subset of the plurality of pre-consolidated tows, and wherein the tow combiner further comprises a plurality of outlets corresponding to the plurality of inlets; and a feed mechanism configured to selectively start and stop movement of a selection of the plurality of pre-consolidated tows from the feedstock source and into the tow combiner to actively alter the shape of a cross-sectional profile of the macro tow along a length of the macro tow as the macro tow is being created, and wherein the feed mechanism is further configured to move the macro tow from the tow combiner. - View Dependent Claims (19, 20)
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Specification