Additive manufacturing system having adjustable curing

• US 10,625,467 B2
• Filed: 07/06/2017
• Issued: 04/21/2020
• Est. Priority Date: 09/06/2016
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: Continuous Composites Inc.
• Inventors: Tyler, Kenneth Lyle
• Primary Examiner(s): Hauth, Galen H
• Application Number:
  US15/642,539
• Publication Number:
  US 20180065298A1
• Time in Patent Office: 1,020 Days
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• 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

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 reinforcement, and a cure enhancer configured to direct energy to the composite material to enhance curing of the matrix. The system may also include an optic adjustably positioned between the cure enhancer and the nozzle of the head.

Claims

1. An additive manufacturing system, comprising:

a head having an outlet configured to discharge a composite material including a matrix and a reinforcement;

a cure enhancer configured to direct energy in a direction to the composite material at the outlet to enhance curing of the matrix, the direction being generally oblique relative to a central axis of the head;

an optic adjustably positioned between the cure enhancer and the outlet of the head; and

a standoff having a central axis generally parallel with the direction of the energy and connecting the optic to the head.

2. The additive manufacturing system of claim 1, wherein the optic includes

at least one lens;

and

at least one pin pivotally connecting the standoff to at least one of the at least one lens and the head.

3. The additive manufacturing system of claim 2, wherein at least one of the

standoff and

the at least one pin allows the at least one lens to selectively pivot completely out of a path of the energy.

4. The additive manufacturing system of claim 2, wherein the standoff facilitates adjustment of a position of the at least one lens along the direction of the energy.

5. The additive manufacturing system of claim 4, wherein the at least one pin additionally facilitates adjustment of an orientation of the at least one lens relative to the direction of the energy.

6. The additive manufacturing system of claim 2, wherein the at least one lens is a convergent lens.

7. The additive manufacturing system of claim 6, wherein the convergent lens is a double convex lens.

8. The additive manufacturing system of claim 6, wherein the convergent lens is one of a plano-convex and concavo-convex lens.

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

the cure enhancer is one of a plurality of cure enhancers; and

the at least one lens includes one lens associated with each of the plurality of cure enhancers.

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

the cure enhancer is one of a plurality of cure enhancers; and

the at least one lens is common to all of the plurality of cure enhancers.

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

12. The additive manufacturing system of claim 1, wherein the optic is manually adjustable.

13. The additive manufacturing system of claim 1, further including:

an actuator associated with the optic; and

a controller configured to;

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

regulate operation of the actuator based on the information.

14. The additive manufacturing system of claim 1, wherein adjustment of the optic varies a cure energy at the outlet.

15. The additive manufacturing system of claim 14, wherein the adjustment of the optic results in a change in a shape of the cure energy at the outlet.

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

17. An additive manufacturing system, comprising:

a head having an outlet configured to discharge a composite material including a matrix and a reinforcement;

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

a light source mounted to the head at the outlet and configured to direct energy to the composite material to enhance curing of the matrix;

at least one lens associated with the light source; and

a mount configured to adjustably connect the at least one lens to the head along a line that extends from light source to the outlet,

wherein adjustment of the at least one lens changes a shape of the energy at the outlet.

18. An additive manufacturing system, comprising:

a head having an outlet configured to discharge a composite material including a matrix and a reinforcement;

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

a light source mounted to the head adjacent the outlet and configured to direct energy to the composite material to enhance curing of the matrix;

a lens disposed in a path of light extending to the outlet of the head; and

a mount configured to selectively pivot the lens completely out of the path of the light.

19. The additive manufacturing system of claim 18, wherein the lens is adjustably mounted to the head to vary a distance of the lens along the path.

20. The additive manufacturing system of claim 18, wherein the lens is adjustably mounted to the head to vary an angular orientation of the lens relative to the path.