Arevo, Inc.

Hemant Bheda

Riley Reese

Wiener Mondesir

Chandrashekar Mantha

Zachary Aaron August

Leonid Michael Treyger

Shekar Mantha

Sohil Nandu

Peter John Woytowitz

Armando Armijo

Paren Shah

An additive manufacturing system is disclosed that comprises two or more lasers for precisely heating a fiber-reinforced thermoplastic feedstock and a fiber-reinforced thermoplastic workpiece in preparation for depositing and tamping the feedstock onto the workpiece. The system employs feedforward, a variety of sensors, and feedback to ensure that the feedstock and workpiece are properly heated.

Heating system for fiber-reinforced thermoplastic feedstock and workpiece

The present disclosure provides methods for generating a three-dimensional object, comprising directing at least one strand material from a source of at least one strand material towards a base. Next, at least a first light beam and a second light beam from a light source is used to subject at least one strand material to heating at one or more locations along at least one strand material. At least a portion of the three-dimensional object may be generated from at least one strand material upon subjecting at least one strand material to heating along one or more locations.

Methods and systems for three-dimensional printing of composite objects

The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.

Localized heating to improve interlayer bonding in 3D printing

The present invention relates to a system and a method for optimizing printing parameters, such as slicing parameters and tool path instructions, for additive manufacturing. The present invention comprises a property analysis module that predicts and analyses properties of a filament object model, representing a constructed 3D object. The filament object model is generated based on the tool path instructions and user specified object properties. Analysis includes comparing the predicted filament object model properties with the user specified property requirements; and further modifying the printing parameters in order to meet the user specified property requirements.

Method and a system to optimize printing parameters in additive manufacturing process

A material for use in a fused filament fabrication (FFF) printer comprises a polyaryletherketone (PAEK) having an amorphous morphology. In some embodiments, the material also includes a PAEK having a semi-crystalline morphology.

Amorphous polyaryletherketone and blends thereof for use in additive manufacturing

An apparatus for manufacturing an object includes an extrusion head having an extrusion needle for extruding thermoplastic material associated with one or more fiber strands. The apparatus may further include a turn-table, a more robotic arm for moving the extrusion head and needle, thermoplastic filament and fiber strand spools and thermoplastic filament and fiber strands. A controller is provided for directing the robotic arm, extrusion head and the turn-table. Further, a method for manufacturing an object includes generating a design for the object that substantially satisfies desired structural properties of the object and generating a sequence for extruding one or more beads of thermoplastic material to manufacture the object according to the design, in which the one or more beads of thermoplastic material are associated with one or more fiber strands. The one or more beads of thermoplastic material and the associated one or more fiber strands are then extruded according to the sequence.

Reinforced fused-deposition modeling

The present invention provides a system and a method for real time monitoring and identifying defects occurring in a three dimensional object build via an additive manufacturing process. Further, the present invention provides in-situ correction of such defects by a plurality of functional tool heads possessing freedom of motion in arbitrary planes and approach, where the functional tool heads are automatically and independently controlled based on a feedback analysis from the printing process, implementing analyzing techniques. Furthermore, the present invention provides a mechanism for analyzing defected data collected from detection devices and correcting tool path instructions and object model in-situ during construction of a 3D object. A build report is also generated that displays, in 3D space, the structural geometry and inherent properties of a final build object along with the features of corrected and uncorrected defects. Advantageously, the build report helps in improving 3D printing process for subsequent objects.

Method to monitor additive manufacturing process for detection and in-situ correction of defects

Methods for producing 3D printing composite polymer materials for use in additive manufacturing processes are provided. The methods result in enhancing the material properties of the printing material by providing a uniform and smooth surface finish of the printing material and the nozzle extrudate for additive manufacturing processes, such as Fused Filament Fabrication. The method includes implementing impregnation techniques for combining carbon nanotubes or other nano-fillers, a polymer resin and a fiber material to produce a polymer material that can be processed into a printing material. Further, the method may include combining the carbon nanotubes or other nano-fillers and the polymer resin to form a masterbatch that may be further combined with the fiber material through an extrusion process. The method results in a printing material with enhanced material properties and smooth surface finish for the printing material and resulting nozzle extrudate for Fused Filament Fabrication.

Method to manufacture polymer composite materials with nano-fillers for use in additive manufacturing to improve material properties

Methods and systems are disclosed for structurally analyzing and/or three-dimensional printing a part. The method may comprise receiving a model of the part for three-dimensional printing from a material comprising a matrix, receiving one or more properties for the material, and using the model, determining a print head tool path for use during the three-dimensional printing of the part. The method may also comprise determining a trajectory of at least one stiffness-contributing portion of the material based at least in part on the print head tool path, determining a performance of the part based at least in part on the one or more properties and the trajectory, and electronically outputting the performance of the part.

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Saratoga, CA, United States of America

Hemant Bheda