Additive manufacturing system having vibrating nozzle

Patent metadata

Field	Value
Publication number	US-10953598-B2
Application number	US-201715618066-A
Country	US
Kind code	B2
Filing date	Jun 8, 2017
Priority date	Nov 4, 2016
Publication date	Mar 23, 2021
Grant date	Mar 23, 2021

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include a nozzle configured to discharge a composite material, including a matrix and a continuous reinforcement. The system may also include a support configured to move the nozzle in multiple dimensions during discharge of the composite material, and a vibration mechanism configured to generate oscillations within the nozzle during discharge.

First claim

What is claimed is:

1. An additive manufacturing system, comprising:
a nozzle configured to discharge a composite material, including a matrix and a continuous reinforcement;
a support configured to move the nozzle in multiple dimensions during discharge of the composite material; and
a vibration mechanism configured to generate oscillations that compacts the composite material after discharge from the nozzle,
wherein the vibration mechanism includes:
a shoe located at a side of the nozzle;
a spring configured to bias the shoe against the composite material; and
an actuator configured to cause the shoe to oscillate in an axial direction of the nozzle.

2. The additive manufacturing system of claim 1 , further including a cure enhancer configured to direct energy to the composite material during discharge to enhance curing of the matrix.

3. The additive manufacturing system of claim 2 , further including a reservoir configured to contain the matrix, wherein:
the nozzle is configured to receive the matrix from the reservoir; and
the vibration mechanism is connected to at least one of the reservoir and the nozzle.

4. The additive manufacturing system of claim 3 , further including a dampener disposed between the cure enhancer and the at least one of the reservoir and the nozzle.

5. The additive manufacturing system of claim 3 , further including:
a housing configured to at least partially enclose the reservoir and the nozzle; and
a dampener disposed between the housing and the at least one of the reservoir and the nozzle.

6. The additive manufacturing system of claim 3 , wherein the vibration mechanism includes at least one of an imbalanced rotary actuator and a spring-biased linear actuator.

7. The additive manufacturing system of claim 6 , further including a controller configured to:
receive information regarding a structure to be manufactured with the composite material; and
coordinate operation of the vibration mechanism with movement of the nozzle based on the information.

8. The additive manufacturing system of claim 1 , wherein:
the vibration mechanism is a first vibration mechanism; and
the additive manufacturing system further includes a second vibration mechanism operatively connected at side of the nozzle opposite the first vibration mechanism.

9. The additive manufacturing system of claim 8 , wherein the second vibration mechanism includes:
a blade;
a spring that biases the blade in an axial direction of the nozzle; and
an actuator configured to cause the blade to oscillate in a direction normal to the axial direction of the nozzle.

10. The additive manufacturing system of claim 9 , further including a roughener connected to a surface of the blade and configured to engage the composite material.

11. The additive manufacturing system of claim 9 , wherein the blade is configured to pivot in a travel direction of the nozzle.

12. The additive manufacturing system of claim 9 , wherein the first vibration mechanism oscillates at a frequency that is about 200 to 250 times an oscillation frequency of the second vibration mechanism.

13. The additive manufacturing system of claim 8 , wherein:
the first vibration mechanism is located at a trailing side of the nozzle relative to a travel direction of the nozzle; and
the second vibration mechanism is located at a leading side of the nozzle.

14. An additive manufacturing system, comprising:
a nozzle configured to discharge a composite material, including a matrix and a continuous reinforcement;
a support configured to move the nozzle in multiple dimensions during discharge of the composite material; and
a vibration mechanism configured to generate oscillations within the nozzle during discharge, wherein:
the vibration mechanism is a first vibration mechanism;
the additive manufacturing system further includes:
a second vibration mechanism operatively connected to the nozzle; and
a controller in communication with the first and second vibration mechanisms; and

the controller is configured to cooperatively energize the first and second vibration mechanisms to produce a desired movement of the nozzle.

15. An additive manufacturing system, comprising:
a nozzle configured to discharge a composite material, including a matrix and a continuous reinforcement;
a support configured to move the nozzle in multiple dimensions during discharging;
a cure enhancer configured to direct energy to the composite material during discharging to enhance curing of the matrix;
a shoe connected to the nozzle at a trailing side relative to a travel direction of the nozzle;
a first spring configured to bias the shoe against the composite material discharging from the nozzle;
a first actuator configured to generate oscillations in the shoe in an axial direction of the nozzle;
a blade connected to the nozzle at a leading side;
a second spring configured to bias the blade in the axial direction of the nozzle; and
a second actuator configured to generate oscillations in the blade in a direction normal to the axial direction of the nozzle.

16. The additive manufacturing system of claim 15 , further including a roughener connected to a surface of the blade and configured to engage composite material.

17. The additive manufacturing system of claim 15 , wherein the shoe oscillates at a frequency that is about 200 to 250 times an oscillation frequency of the blade.

Assignees

• Cc3D Llc
• Continuous Composites Inc

Inventors

• Tyler Kenneth Lyle
• Budge Trevor David

Classifications

• B33Y70/10

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

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/307

  Handling of material to be used in additive manufacturing · CPC title

• B29C2035/0827

  using UV radiation · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title