Control methods for additive manufacturing system

• US 10,647,058 B2
• Filed: 06/02/2017
• Issued: 05/12/2020
• Est. Priority Date: 09/06/2016
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: Continuous Composites Inc.
• Inventors: Tyler, Kenneth Lyle, Alfson, Blake L., Coad, Josiah D., Beebout, Kaleb Forrest
• Primary Examiner(s): Malekzadeh, Seyed Masoud
• Assistant Examiner(s): Cummins, IV, Manley L
• Application Number:
  US15/603,328
• Publication Number:
  US 20180065322A1
• Time in Patent Office: 1,075 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 method is disclosed for controlling an additive manufacturing system. The method may include causing a head to discharge composite material along a first trajectory, and activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory. The method may also include selectively deactivating the cure enhancer as the head nears a corner location, moving the head to a second trajectory after the head reaches the corner location, and reactivating the cure enhancer after moving the head to the second trajectory.

Claims

1. A method for controlling an additive manufacturing system, comprising:

causing a head to discharge composite material along a first trajectory;

activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory;

selectively deactivating the cure enhancer as the head nears a corner location;

moving the head to a second trajectory after the head reaches the corner location; and

reactivating the cure enhancer after moving the head to the second trajectory;

wherein;

causing the head to discharge composite material includes causing the head to move at a first travel speed;

the method further includes stepping up a travel speed of the head to a second travel speed higher than the first travel speed as the head is moving to the second trajectory;

stepping up the travel speed includes momentarily stepping up the travel speed; and

the method further includes dropping the travel speed of the head to a third travel speed slower than the first travel speed after the head reaches the second trajectory.

2. The method of claim 1, further including causing the head to discharge a minimum length of the composite material while the cure enhancer is deactivated at the corner location.

3. The method of claim 2, wherein the cure enhancer generates an area of irradiance on composite material discharging from the head.

4. The method of claim 3, wherein the minimum length is about equal to a radius of the area of irradiance.

5. The method of claim 4, wherein selectively deactivating the cure enhancer includes deactivating the cure enhancer as a leading edge of the area of irradiance reaches the corner location.

6. The method of claim 2, wherein causing the head to discharge a minimum length of composite material includes causing the head to continue discharging composite material along the first trajectory past the corner location.

7. The method of claim 6, wherein moving the head includes pivoting the head through an arc while maintaining the minimum length of the composite material taut.

8. The method of claim 7, further including causing the head to rotate in a direction of the pivoting during pivoting.

9. The method of claim 1, wherein moving the head includes pivoting the head through at least 90°

.

10. The method of claim 9, wherein pivoting the head includes pivoting the head through about 180°

.

11. The method of claim 1, further including ramping up the travel speed of the head from the third travel speed to the first travel speed.

12. The method of claim 1, further including pausing movement of the head at the corner location.

13. The method of claim 1, further including causing the head to move in a direction generally orthogonal to the first trajectory after the head reaches the corner location and before moving the head to the second trajectory.

14. The method of claim 1, further including:

receiving information associated with the corner location; and

tracking movement of the head relative to the corner location.

15. A method for controlling an additive manufacturing system, comprising:

causing a head to discharge composite material along a first trajectory toward a corner location;

causing the head to discharge a minimum length of composite material after the head has passed the corner location during movement along the first trajectory; and

moving the head and the minimum length of the composite material to a second trajectory;

wherein;

causing the head to discharge the composite material along the first trajectory includes causing the head to move at a first travel speed; and

the method further includes;

momentarily stepping up a travel speed of the head to a second travel speed higher than the first travel speed after the head has been moved to the second trajectory;

dropping the travel speed of the head to a third travel speed slower than the first travel speed after momentarily stepping up the travel speed; and

ramping up the travel speed of the head from the third travel speed to the first travel speed.

16. The method of claim 15, wherein moving the head includes pivoting the head through an arc while maintaining the minimum length of composite material taut.