Additive manufacturing system having adjustable energy shroud

• US 10,603,840 B2
• Filed: 06/08/2017
• Issued: 03/31/2020
• Est. Priority Date: 09/06/2016
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: Continuous Composites Inc.
• Inventors: Tyler, Kenneth Lyle, Mueller, Martin S.
• Primary Examiner(s): Malekzadeh, Seyed Masoud
• Assistant Examiner(s): Cummins, IV, Manley L
• Application Number:
  US15/617,052
• Publication Number:
  US 20180065316A1
• Time in Patent Office: 1,027 Days
• Field of Search: None
• CPC Class Codes: B05D 1/26 performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
• CPC Class Codes: B25J 9/026 Gantry-type
• CPC Class Codes: B25J 9/046 Revolute coordinate type
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/2556 provided in or in the proximity of dies B29C48/302, B29C48/31, B29C48/325 take precedence
• CPC Class Codes: B29C 48/266 Means for allowing relative movements between the apparatus parts, e.g. for twisting the extruded article or for moving the die along a surface to be coated
• CPC Class Codes: B29C 48/30 Extrusion nozzles or dies extrusion characterised by the shape or cross-section of the extruded article B29C48/03
• CPC Class Codes: B29C 48/301 having reciprocating, oscillating or rotating parts
• CPC Class Codes: B29C 48/304 specially adapted for bringing together components, e.g. melts within the die
• 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 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 70/384 Fiber placement heads, e.g. component parts, details or accessories
• CPC Class Codes: B29K 2105/0058 Liquid or visquous
• CPC Class Codes: B29K 2105/08 : of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• 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: B33Y 70/10 : Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a composite material including a matrix and a plurality of continuous reinforcements. The system may also include a cure enhancer configured to direct energy to the composite material to enhance curing of the matrix, and a shroud adjustably mounted to the head and configured to selectively block at least some of the energy from reaching the matrix.

Claims

1. An additive manufacturing system, comprising:

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

a cure enhancer configured to direct energy to the composite material to enhance curing of the matrix; and

a shroud adjustably mounted relative to the nozzle tip and configured to selectively block at least some of the energy from reaching the matrix at a discharge location of the nozzle tip.

2. The additive manufacturing system of claim 1, wherein the cure enhancer is mounted to the head.

3. The additive manufacturing system of claim 1, wherein the shroud is mounted to the nozzle tip and adjustable in an axial direction of the nozzle tip.

4. The additive manufacturing system of claim 1, further including a manual adjustment component configured to fix a position of the shroud relative to the head.

5. The additive manufacturing system of claim 4, wherein the manual adjustment component is a setscrew.

7. The additive manufacturing system of claim 1, further including at least one of a piston and a leadscrew configured to adjust a position of the shroud relative to the nozzle tip.

8. The additive manufacturing system of claim 1, wherein the shroud includes a cylindrical body configured to at least partially surround the nozzle tip of the head.

9. The additive manufacturing system of claim 8, wherein the shroud further includes an outer annular rim that flares radially outward at an end adjacent the discharge location of the nozzle tip.

10. The additive manufacturing system of claim 1, wherein the shroud creates a circular energy shadow at the discharge location of the nozzle tip.

11. The additive manufacturing system of claim 1, further including a support configured to move the head in multiple dimensions during discharging.

19. The additive manufacturing system of claim 1, wherein the shroud is fabricated from a light deflecting material and shaped to generate an annular area of greatest energy intensity radially outward of the shroud.

6. An additive manufacturing system, comprising:

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

a cure enhancer configured to direct energy to the composite material to enhance curing of the matrix;

a shroud adjustably mounted to the head and configured to selectively block at least some of the energy from reaching the matrix;

an actuator configured to automatically adjust a position of the shroud relative to the head;

a controller configured to;

receive information regarding a structure to be manufactured with the composite material; and

coordinate operation of the actuator with movement of the head based on the information.

20. The additive manufacturing system of claim 6, wherein the shroud is fabricated from a light deflecting material and shaped to generate an annular area of greatest energy intensity radially outward of the shroud.

12. An additive manufacturing system, comprising:

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

a support configured to move the head in multiple dimensions during discharging;

a cure enhancer mounted to the head and configured to direct energy to the composite material after discharge to enhance curing of the matrix; and

a shroud mounted to the nozzle tip and configured to selectively block at least some of the energy generated by the cure enhancer from reaching the matrix at a discharge location of the nozzle tip, the shroud being adjustable relative to the nozzle tip in an axial direction of the nozzle tip.

13. The additive manufacturing system of claim 12, further including a manual adjustment component configured to fix an axial position of the shroud relative to the nozzle tip.

14. The additive manufacturing system of claim 12, further including an actuator configured to automatically adjust an axial position of the shroud relative to the nozzle tip.

15. The additive manufacturing system of claim 14, further including a controller configured to:

receive information regarding a structure to be manufactured with the composite material; and

coordinate operation of the actuator with movement of the head based on the information.

16. The additive manufacturing system of claim 12, wherein the shroud creates a circular energy shadow at the discharge location of the nozzle tip.

17. An additive manufacturing system, comprising:

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

a cure enhancer mounted to the head and configured to direct energy to the composite material after discharge to enhance curing of the matrix;

a shroud configured to selectively block at least some of the energy from reaching the matrix at a discharge location of the head;

an actuator configured to automatically adjust a position of the shroud relative to the head; and

a controller configured to;

receive information regarding a structure to be manufactured with the composite material; and

coordinate operation of the actuator with movement of the head based on the information, such that a corresponding amount of energy from the cure enhancer is absorbed by the discharging composite material at a desired location along a planned trajectory.

18. The additive manufacturing system of claim 17, wherein the shroud creates a circular energy shadow at a discharge location of the head.