Continuous Composites Inc.

Mikel Negugogor

Logan Lalonde

Rachael Kathleen Morris

Brock Adam Jahner

Ryan C Stockett

Nathan Andrew Stranberg

Stephen Tyler Wilson

Maxwell Joseph Johnson

Chase Bosman

Christopher Losee

Dan Budge

Methods and associated systems and apparatus are disclosed for determining a tool path for use in additively manufacturing a structure. The methods may include identifying a propagation surface onto which material forming at least part of the structure is to be deposited, and determining a structure boundary associated with the propagation surface and defining at least part of the structure. The methods may also include determining one or more structure layers offset from the propagation surface and laterally bounded by the structure boundary; generating a tool path for each structure layer.

Systems and methods for controlling additive manufacturing

Methods and associated systems and apparatus for determining a tool path for use in additively manufacturing a structure. The methods may include receiving data that at least partially defines an outer boundary for a region of the structure, partitioning the region based on placement of a partitioning line across the region from the outer boundary, and generating the tool path to navigate at least part of the outer boundary and to cross, at least partially, the region based on the placement of the partitioning line.

Methods and associated systems and apparatus for determining a tool path for use in additively manufacturing a structure. The methods may include receiving placement data indicative of a relative placement of a plurality of nodes, each node including one or more regional tool paths and each regional tool path for additively manufacturing a region of the structure. The methods may also include receiving operation data indicative of an operation to be performed in relation to at least one of the plurality of nodes, and resolving the at least one of the plurality of nodes into a resolved tool path for use in additively manufacturing the structure based on the received placement data and operation data.

A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths within a first layer. Each of the first plurality of paths may have a center portion, a first portion extending away from the center portion to at least partially form a first branch, and a second portion integral extending away from the center portion opposite the first portion to at least partially form a second branch. The method may further include depositing a second plurality of paths primarily within the first layer. Each of the second plurality of paths may have a center portion, and a first portion extending away from the center portion to at least partially form a third branch of the joint. The second plurality of paths may cross over and be bonded to the first plurality of paths to form spaced-apart bumps that extend into a second layer.

Systems and methods of additive manufacturing

A method is disclosed for manufacturing a joint. The method may include depositing a first path of composite material within a first layer at the joint. The first path may have a center at a center of the joint, a first portion integral with the center portion and extending away from the center portion, and a second portion integral with the center and extending away from the center portion. The method may further include depositing a second path of composite material within the first layer at the joint. The second path may have a center at the center of the joint, and a first portion integral with the center of the second path and extending away from the center of the second path. The center portion of the second path may be parallel with, abut and be bonded to the center portion of the first path.

Systems and methods for additive manufacturing

A method is disclosed for additively manufacturing a composite structure. The method may include receiving from a user a sketch of a cross-section of the composite structure and a desired height. The method may also include automatically generating a virtual model of the composite structure having a plurality of layers, each with a thickness related to the height. The method may further include receiving from the user at least one infill pattern for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a continuous fiber along segments of the at least one infill pattern.

A method is disclosed for additively manufacturing a structure. The method may include slicing a virtual model of the structure into a plurality of layers, applying at least one infill pattern to each of the plurality of layers, and distributing a plurality of points along lines of the at least one infill pattern. The method may also include sequentially grouping the plurality of points into at least one path, validating the at least one path for fabrication by an additive manufacturing machine, and causing the additive manufacturing machine to discharge material along the validated at least one path.

A method is disclosed for use in additively manufacturing a composite structure from reinforcements wetted with a matrix. The method may include slicing a virtual model of the composite structure into multiple slices that are adjacent to each other along a length direction of the composite structure and determining points of the reinforcements passing through each of the multiple slices. The method may further include clocking the points differently around each of the multiple slices and generating at least one tool path including a sequenced subset of the points. The method may additionally include causing an additive manufacturing machine to discharge the reinforcements along the at least one tool path.

System and method for additive manufacturing

A method is disclosed for additively manufacturing a structure. The method may include generating a vector field through a 3D virtual model, and slicing the virtual model into a plurality of layers that are aligned with the vector field. The method may also include generating at least one tool path for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a material along the at least one tool path.

A method is disclosed for additively manufacturing a structure. The method may include generating at least one tool path, causing the additive manufacturing machine to place material along a first portion of the at least one tool path, and monitoring placement of the material along the first portion of the at least one tool path. The method may also include adjusting a second portion of the at least one tool path based on the placement, and causing the additive manufacturing machine to place material along the second portion of the at least one tool path after the adjusting.

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Coeur d'Alene, ID, United States of America

Mikel Negugogor