Continuous Composites Inc.

Cc3d LLC

Blake L Alfson

Kenneth Lyle Tyler

Ryan C Stockett

Josiah D Coad

Trevor David Budge

Kaleb Forrest Beebout

Tyler B Alvarado

A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to determine a plurality of tension vectors to be generated within the structure, and to generate a plan for manufacturing the structure. The plan may include tool paths that arrange continuous fibers within the structure to generate the plurality of tension vectors. The processor may also be configured to execute the computer-executable instructions to cause the additive manufacturing machine to follow the plan and manufacture the structure.

Systems and methods for controlling additive manufacturing

A system is disclosed for additively manufacturing a composite structure. The system may include a head having a matrix reservoir, a nozzle fluidly connected to the matrix reservoir and configured to discharge a composite material into a feature of an existing component. a guide configured to detect a location of the feature, and a cure enhancer configured to expose composite material discharging from the nozzle to a cure energy. The system may also include a support configured to move the head in multiple dimensions, and a controller in communication with the cure enhancer and the support. The controller may be configured to cause the support to move the head during discharge of the composite material into the feature based on the detected location of the feature.

System and method for additively manufacturing functional elements into existing components

A method is disclosed for controlling an additive manufacturing system. The method may include causing a head to discharge composite material along a first trajectory, and activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory. The method may also include selectively deactivating the cure enhancer as the head nears a corner location, moving the head to a second trajectory after the head reaches the corner location, and reactivating the cure enhancer after moving the head to the second trajectory.

Control methods for additive manufacturing system

A nozzle is disclosed for use with an additive manufacturing system. The nozzle may include a first channel fluidly connectable to a matrix reservoir and configured to discharge a liquid matrix received from the matrix reservoir. The nozzle may also include a second channel operatively connected to the first channel configured to discharge a reinforcement into a bed of the liquid matrix discharged by the first channel.

A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to cause the additive manufacturing machine to discharge a path of composite material, including a continuous fiber and a matrix at least partially coating the continuous fiber. The processor may also be configured to execute the computer-executable instructions to monitor an energy level within the continuous fiber during discharging, to make a determination that the continuous fiber has lost continuity based on a reduction in the energy level, and to selectively interrupt the discharging based on the determination.

A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to make a determination associated with the structure being a performance-critical part and, based on the determination, selectively implement a first slicing technique or a second slicing technique to divide a virtual model of the structure into a plurality of planes. The processor may be further configured to execute the computer-executable instructions to cause the additive manufacturing machine to deposit composite material in layers corresponding to the plurality of planes.

A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to determine if a tool path to be followed by the additive manufacturing machine during manufacture of the structure is located in free-space or on top of another tool path. When the tool path is located in free-space, the processor may be further configured to execute the computer-executable instructions to make a determination regarding a curvature of the tool path, and to selectively cause the additive manufacturing machine to fabricate a support for the tool path based on the determination.

A method is disclosed for additively manufacturing a composite structure. The method may include discharging from a nozzle into a feature of an existing component a first track of material including at least a liquid matrix. The method may also include discharging from the nozzle into the first track of material a second track of material including at least one of a wire and an optical fiber, and curing the liquid matrix.

A method is disclosed for additively manufacturing a composite wiring harness. The method may include directing a plurality of conductors through a print head, directing at least one reinforcement through the print head, and coating at least one of the plurality of conductors and the at least one reinforcement with a matrix material. The method may also include discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material from the print head, and exposing the matrix material during discharging to a cure energy to cause hardening of a sheath around the plurality of conductors.

System and method for additively manufacturing composite wiring harness

A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to cause the additive manufacturing machine to discharge a path of composite material, and to make a determination regarding existence of support located at a side of the path of composite material. The processor may be further configured to execute the computer-executable instructions to selectively cause the additive manufacturing machine to compact the path of composite material after discharge with a variable pressure that is based on the determination.

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Hayden Lake, ID, United States of America

Blake L Alfson