ADDITIVE MANUFACTURING TECHNIQUES AND SYSTEMS TO FORM COMPOSITE MATERIALS

• US 20160136897A1
• Filed: 11/13/2015
• Published: 05/19/2016
• Est. Priority Date: 11/14/2014
• Status: Active Grant

• Current Assignee: Orbital Composites, Inc.
• Original Assignee: Cole Nielsen-Cole, James Frei
• Inventors: Frei, James, NIELSEN-COLE, Cole
• Granted Patent: US 10,293,591 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29B 7/90 Fillers or reinforcements , e.g. fibres
• CPC Class Codes: B29C 48/0021 combined with joining, lining or laminating
• CPC Class Codes: B29C 48/02 Small extruding apparatus, e.g. handheld, toy or laboratory extruders
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• 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 48/304 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: B29C 48/865 Heating
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/194 during lay-up
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/218 Rollers
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29L 2031/16 Frictional elements, e.g. brake or clutch linings
• 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 printer system may include a coaxial extruder head that extrudes a core, a bulk, and/or a core and bulk cladding to form complex structures without retooling. The coaxial extruder head may include a distribution channel with an entrance and an exit, a priming chamber that surrounds the distribution channel. The priming chamber may include an outlet and a first inlet, a heating element thermally connected to the priming chamber, and a nozzle connected to the outlet of the priming chamber. Further, the nozzle may converge from the outlet of the priming chamber to an orifice of the nozzle. In addition, the exit of the distribution channel may be disposed at the orifice of the nozzle. This structure facilitates extruding a core and cladding type composite from the extruder head.

Claims

1. An extruder head for a printer comprising:

a first distribution channel with an entrance and an exit;

a second distribution channel with an entrance and an exit;

a priming chamber disposed at the exit of the second distribution channel;

a heating element disposed along the second distribution channel and near the priming chamber; and

a nozzle disposed at an exit of the priming chamber.

2. The extruder head of claim 1, further comprising:

a first insertion actuator configured to insert a first material into the entrance of the first distribution channel; and

a second insertion actuator configured to insert a second material into the entrance of the second distribution channel.

3. The extruder head of claim 1, wherein the priming chamber surrounds the first distribution channel.

4. The extruder head of claim 1, further comprising a blade disposed proximate to the exit of the first distribution channel and proximate to the nozzle of the priming chamber.

5. The extruder head of claim 1, further comprising a thermal barrier interposed between the exit and an entrance of the second distribution channel.

6. The extruder head of claim 1, further comprising:

a cutting chamber disposed above or within the priming chamber and bisecting the first distribution channel; and

a blade within the cutting chamber.

7. The extruder head of claim 1, wherein the exit of the first distribution channel and the nozzle of the priming chamber are adjacent.

8. An active molding system comprising:

a printer having an extruder head; and

a shaping actuator configured to follow a displacement of the extruder head, wherein the shaping actuator includes;

a pressure regulator configured to maintain a defined pressure applied to an exposed layer of material, and

a foot unit that shapes the exposed layer of material; and

a controller configured to control the printer and the shaping actuator.

9. The active molding system of claim 8, wherein the foot unit of the shaping actuator is a roller.

10. The active molding system of claim 8, wherein the shaping actuator includes a continuous tread.

11. The active molding system of claim 8, wherein the shaping actuator includes an air nozzle configured to force air to impinge on the exposed layer of material.

12. The active molding system of claim 8, wherein the foot unit of the shaping actuator is one of cambered or flat.

13. The active molding system of claim 8, wherein the shaping actuator includes a blade.

14. The active molding system of claim 13, further comprising a pulsator that pulses the blade between a first position and a second position.

15. The active molding system of claim 8, wherein

the shaping actuator includes a temperature regulator configured to maintain a defined temperature at the exposed layer of material, and

the controller is configured to control the temperature regulator.

16. The active molding system of claim 15, wherein the temperature regulator includes one or both of a temperature sensor or a heating element.

17. The active molding system of claim 16, wherein the heating element is an electrical heating element.

18. The active molding system of claim 16, further comprising a laser configured to heat the exposed layer, and

the controller is configured to control the laser.

19. The active molding system of claim 18, wherein the laser outputs in one of an ultraviolet spectrum or infrared spectrum.

20. The active molding system of claim 8, wherein the foot unit includes an actuator that generates sonic or ultrasonic pulses.