Additive manufacturing system implementing anchor curing

Patent metadata

Field	Value
Publication number	US-10857726-B2
Application number	US-201715846372-A
Country	US
Kind code	B2
Filing date	Dec 19, 2017
Priority date	Jan 24, 2017
Publication date	Dec 8, 2020
Grant date	Dec 8, 2020

Abstract

A system for additively manufacturing a composite structure is disclosed. The system may include a print head configured to discharge a matrix-coated reinforcement, and a support configured to move the print head in multiple dimensions during discharging of the matrix-coated reinforcement. The system may further include at least one cure enhancer located offboard the print head, and a controller in communication with the support and the at least one cure enhancer. The controller may be configured to selectively activate the at least one cure enhancer to expose the matrix-coated reinforcement to a cure energy during discharging of the matrix-coated reinforcement.

First claim

What is claimed is:

1. A method of additively manufacturing a composite structure, comprising:
discharging from a print head a matrix-coated reinforcement;
moving the print head in multiple dimensions during discharging of the matrix-coated reinforcement; and
exposing the matrix-coated reinforcement to a cure energy during discharging of the matrix-coated reinforcement by activating one or more of a plurality of cure energy sources located offboard the print head, wherein said activation of the one or more plurality of cure energy sources located offboard of the print head is based on a proximity of the print head discharging the matrix-coated reinforcement to a respective one or more of the plurality of cure energy sources.

2. The method of claim 1 , wherein:
discharging from the print head the matrix-coated reinforcement includes discharging the matrix-coated reinforcement into a print chamber; and
activating the one or more of the plurality of cure energy sources includes activating the one or more of the plurality of cure energy sources at a surface of the print chamber.

3. The method of claim 1 , wherein:
discharging from the print head the matrix-coated reinforcement includes discharging the matrix-coated reinforcement into a print chamber; and
activating the one or more of the plurality of cure energy sources includes directing the cure energy through a surface of the print chamber.

4. The method of claim 1 , wherein:
discharging from the print head the matrix-coated reinforcement includes discharging the matrix-coated reinforcement onto an anchor point that extends inward from a print chamber wall, and moving the print head away from the anchor point to cause the matrix-coated reinforcement to be pulled from the print head; and
activating the one or more of the plurality of cure energy sources located offboard the print head includes exposing the matrix-coated reinforcement to cure energy from the anchor point.

5. The method of claim 1 , further selectively exposing the matrix-coated reinforcement to a cure energy from onboard the print head.

6. The method of claim 5 , wherein selectively exposing the matrix-coated reinforcement to the cure energy from onboard the print head includes selectively activating a cure source having a different energy characteristic from the cure energy to which the matrix-coated reinforcement is exposed to from offboard the print head.

7. A method of additively manufacturing a composite structure, comprising:
discharging from a print head a composite material that hardens when exposed to a cure energy;
moving the print head during discharging; and
activating one or more of a plurality of available cure energy sources located off board of the print head, wherein said activation is based on a proximity of the print head, during discharging of the composite material, to the one or more of the plurality of energy cure sources located off board of the printhead.

8. The method of claim 7 , wherein activating the one or more of the plurality of available cure energy sources includes activating a stationary source.

9. The method of claim 8 , wherein:
discharging from the print head includes discharging into a print chamber; and
activating the one or more of the plurality of available cure energy sources includes selectively exposing the composite material to the cure energy from a surface of the print chamber.

10. The method of claim 8 , wherein:
discharging from the print head includes discharging into a print chamber; and
activating the one or more of the plurality of available cure energy sources includes directing light through the surface of the print chamber.

11. The method of claim 8 , wherein:
discharging from the print head includes discharging onto an anchor point that extends inward from a print chamber wall, and moving the print head away from the anchor point to cause the composite material to be pulled from the print head; and
activating the one or more of the plurality of available cure energy sources includes selectively exposing the composite material to the cure energy from the anchor point.

12. The method of claim 11 , wherein:
discharging from the print head includes discharging into a print chamber; and
activating the one or more of the plurality of available cure energy sources further includes selectively exposing the composite material to the cure energy from a surface of the print chamber.

13. The method of claim 8 , further including selectively exposing the composite material to additional cure energy from onboard the print head.

14. The method of claim 13 , wherein selectively exposing the composite material to additional cure energy from onboard the print head includes selectively exposing the composite material to a cure energy having a characteristic different from the cure energy to which the material is exposed from offboard the print head.

15. The method of claim 14 , wherein at least one of the cure energy and the additional cure energy is light energy.

Assignees

• Cc3D Llc
• Continuous Composites Inc

Inventors

• Tyler Kenneth Lyle
• Stockett Ryan C

Classifications

• B29C48/12 Primary

  Articles with an irregular circumference when viewed in cross-section, e.g. window profiles · CPC title

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title

• B22F10/12

  by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP] · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title