Print head and method for additive manufacturing system

Patent metadata

Field	Value
Publication number	US-2025289179-A1
Application number	US-202519080491-A
Country	US
Kind code	A1
Filing date	Mar 14, 2025
Priority date	Mar 15, 2024
Publication date	Sep 18, 2025
Grant date	—

Abstract

An additive manufacturing system is disclosed. The additive manufacturing system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material, and a compaction module configured to compact the material. The additive manufacturing system may also include a controller configured to selectively adjust a pressure applied by the compaction module on the material independent of movement of the print head caused by the support.

First claim

What is claimed is:

1 . An additive manufacturing system, comprising:
a support; a print head operatively connected to and moveable by the support, the print head including:
an outlet configured to discharge a material; and
a compaction module configured to compact the material; and
a controller configured to selectively adjust a pressure applied by the compaction module on the material independent of movement of the print head caused by the support.

2 . The additive manufacturing system of claim 1 , wherein:
the compaction module includes:
a compactor; and
an actuator configured to press the compactor towards the material; and
the controller is configured to cause the actuator to adjust a force exerted by the actuator on the compactor.

3 . The additive manufacturing system of claim 2 , wherein:
the compaction module further includes at least one sensor configured to generate a signal indicative of the force exerted by the actuator on the compactor; and the controller is configured to cause the actuator to adjust the force based on the signal.

4 . The additive manufacturing system of claim 3 , wherein:
the compaction module further includes at least one beam connecting the support to the compaction module; and the signal is indicative of a force passing through the at least one beam.

5 . The additive manufacturing system of claim 4 , wherein:
the at least one beam includes:
a first beam attached to the support; and
a second beam oriented orthogonal to the first beam and attached to the first beam and to the compactor; and
the at least one sensor includes:
a first strain gauge associated with the first beam; and
a second strain gauge associated with the second beam.

6 . The additive manufacturing system of claim 3 , wherein the controller is further configured to:
determine an amount of tension in the material based on the signal; and selectively adjust a feed rate of the material based on the tension.

7 . The additive manufacturing system of claim 2 , wherein the actuator is a linear magnet motor.

8 . The additive manufacturing system of claim 2 , further including a breakaway link connecting the actuator to the compactor.

9 . The additive manufacturing system of claim 8 , further including a kick-out mechanism configured to exert a force that separates the compactor from the actuator upon breakage of the breakaway link.

10 . The additive manufacturing system of claim 2 , wherein the print head further includes:
a mounting plate; a bracket operatively connecting the actuator to the compaction module; and at least one carriage connecting the bracket to the mounting plate.

11 . The additive manufacturing system of claim 2 , further including a cutting module configured to be moved with the compaction module by the actuator.

12 . The additive manufacturing system of claim 11 , further including a second actuator configured to move the cutting module relative to the compaction module.

13 . The additive manufacturing system of claim 12 , wherein the second actuator is pneumatically powered or electrically powered.

14 . The additive manufacturing system of claim 13 , further including a third actuator configured to activate the cutting module.

15 . The additive manufacturing system of claim 14 , wherein:
the cutting module includes a rotary cutter; the third actuator is configured to rotate the rotary cutter; and the third actuator is axially offset from the rotary cutter.

16 . The additive manufacturing system of claim 1 , wherein:
the compaction module includes a strain gauge configured to generate a signal indicative of the force exerted by the actuator on the compactor; and the controller is configured to adjust the pressure based on the signal.

17 . The additive manufacturing system of claim 1 , wherein the compaction module includes:
a rolling compactor; and a rigid wiper trailing the rolling compactor.

18 . The additive manufacturing system of claim 1 , wherein the compaction module includes:
at least one energy transmitter; and a shield generator configured to shield a tip of the at least one energy transmitter from vapor.

19 . The additive manufacturing system of claim 1 , wherein:
the compaction module includes an energy transmitter; the additive manufacturing system further includes a calibration device located on a base of the support and configured to detect an amount of energy discharging from the energy transmitter; and the controller is configured to calibrate the energy transmitter based on the detected amount of energy discharging from the energy transmitter.

20 . A method of controlling a compaction module of an additive manufacturing system, comprising:
discharging a material from a print head; moving a compaction module over the material to compact the material, wherein the material exerts a first force on the compaction module due to tension in the material; activating a linear magnet motor to exert a second force on the compaction module in a first direction during moving of the compaction module over the material; detecting a first component of the first force passing through a first beam supporting the compaction module, the first component of the first force acting in a second direction orthogonal to the first direction; making a determination of an amount of the second force acting on the material as a function of the component of the first force; and adjusting the second force based on the determination.

Assignees

• Continuous Composites Inc

Inventors

• Wilson Stephen Tyler
• Milbourne Michael John
• Armstrong Sam
• Vandenberg Samuel
• Overby Andrew John
• Doudy Christopher James
• Losee Christopher C

Classifications

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/194

  during lay-up · CPC title

• B29C64/209 Primary

  Heads; Nozzles · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title