Additive manufacturing system implementing in-situ anchor-point fabrication

Patent metadata

Field	Value
Publication number	US-10864677-B2
Application number	US-201715798646-A
Country	US
Kind code	B2
Filing date	Oct 31, 2017
Priority date	Nov 4, 2016
Publication date	Dec 15, 2020
Grant date	Dec 15, 2020

Abstract

An additive manufacturing system may include a head configured to discharge a matrix-coated reinforcement, a support configured to move the head during discharging, and a cure enhancer configured to cure the matrix as the matrix-coated reinforcement discharges from the head. The additive manufacturing system may also include a controller in communication with the head, the support, and the cure enhancer. The controller may be configured to receive specifications for a structure to be fabricated, and to determine an anchor point from which the matrix-coated reinforcement will be pulled during fabrication of the structure. The controller may also be configured to regulate operation of the head, the support, and the cure enhancer to manufacture the structure and the anchor point.

First claim

What is claimed is:

1. An additive manufacturing system, comprising:
a head configured to discharge a matrix-coated reinforcement;
a support configured to move the head during discharging;
a cure enhancer configured to cure a matrix in the matrix-coated reinforcement as the matrix-coated reinforcement discharges from the head; and
a controller in communication with the head, the support, and the cure enhancer, the controller being configured to:
receive specifications for a structure to be fabricated;
determine an anchor from which the matrix-coated reinforcement will be pulled during fabrication of the structure; and
regulate operation of the head, the support, and the cure enhancer to:
manufacture the anchor;
adhere the matrix-coated reinforcement to a point on the anchor; and
move the head away from the anchor to pull the matrix-coated reinforcement from the head.

2. The additive manufacturing system of claim 1 , wherein the controller is configured to determine the anchor based on a trajectory of the matrix-coated reinforcement within the structure.

3. The additive manufacturing system of claim 2 , wherein the controller is configured to determine the anchor based further on a force vector specified for the matrix-coated reinforcement.

4. The additive manufacturing system of claim 2 , wherein the controller is configured to determine the anchor based further on a magnitude of tensile stress to be induced in the matrix-coated reinforcement.

5. The additive manufacturing system of claim 1 , wherein the controller is configured to determine a number, location, orientation, size, and shape of the anchor.

6. The additive manufacturing system of claim 1 , wherein the controller is configured to regulate operation of the head, the support, and the cure enhancer to manufacture the anchor on a print chamber surface.

7. The additive manufacturing system of claim 1 , wherein the controller is configured to regulate operation of the head, the support, and the cure enhancer to manufacture the anchor on the structure.

8. The additive manufacturing system of claim 1 , wherein the anchor is adjustable after manufacture.

9. The additive manufacturing system of claim 8 , wherein the anchor is manufactured on a moveable fixture.

10. The additive manufacturing system of claim 1 , wherein the anchor includes a functional element.

11. The additive manufacturing system of claim 10 , wherein the functional element is only temporarily connected to the structure.

12. The additive manufacturing system of claim 10 , wherein the functional element becomes a permanent part of the structure.

13. The additive manufacturing system of claim 1 , wherein the anchor is manufactured from the matrix-coated reinforcement.

14. The additive manufacturing system of claim 1 , wherein the anchor is manufactured from only a matrix.

15. The additive manufacturing system of claim 1 , wherein the structure is only tethered to the anchor.

16. The additive manufacturing system of claim 1 , wherein the structure is tethered to the anchor by at least one of an uncured matrix-coated reinforcement or an uncoated reinforcement.

17. The additive manufacturing system of claim 1 , wherein the structure extends in multiple directions away from the anchor.

18. An additive manufacturing system, comprising:
a head configured to discharge a matrix-coated reinforcement;
a support configured to move the head during discharging;
a cure enhancer configured to cure a matrix in the matrix-coated reinforcement as the matrix-coated reinforcement discharges from the head; and
a controller in communication with the head, the support, and the cure enhancer, the controller being configured to:
determine a tensile force vector specified for a structure to be manufactured;
determine a number and location of an anchor required to provide reactionary support against the tensile force vector; and
regulate operation of the head, the support, and the cure enhancer to:
manufacture the anchor;
adhere the matrix-coated reinforcement to a point on the anchor; and
move the head away from the anchor to pull the matrix-coated reinforcement from the head.

19. The additive manufacturing system of claim 18 , wherein the anchor includes a functional element that becomes a permanent part of the structure.

Assignees

• Cc3D Llc
• Continuous Composites Inc

Inventors

• Tyler Kenneth L
• Stockett Ryan C

Classifications

• B33Y70/10

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

• B29C70/384

  Fiber placement heads, e.g. component parts, details or accessories · CPC title

• B29C64/259

  Interchangeable · CPC title

• B29K2105/08

  of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns · CPC title

• B29C64/295

  Heating elements · CPC title