Ut-battelle, Inc.

Seokpum Kim

Vlastimil Kunc

Ahmed A Hassen

John M Lindahl

Lonnie J Love

Chad Edward Duty

Brian K Post

Phillip C Chesser

Alex C Roschli

Jordan A Failla

Ahmed Arabi Hassen

Michael C Borish

Gregory D Dreifus

Craig A Blue

Pooran Chandra Joshi

Thomas A Feldhausen

John C Bowers

Tyler C H Smith

Vipin Kumar

Christopher J Hershey

Vlastimil Kune

Bentley T Beard, Ii

Kenneth Stephenson

Slicer system for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.

Slicer systems for generating a molecular dynamic graded lattice structure and their application to additive manufacturing

The current embodiments include all-polymeric protective material for mitigating lightning strike damage. The protective material includes a hybrid matrix comprising PANI and MXene dispersed within a thermosetting epoxy resin. This hybrid matrix can be painted, printed, or applied as a conductive polymeric layer to a FRCP structure, for example an aircraft fuselage, wing, empennage, control surface (aileron, flap, slats, rudder, elevator) or a wind turbine blade. The protective material not only withstands lightning strikes, but also functions as shielding against electromagnetic interference and is corrosion-resistant and lightweight.

3D printable polymeric lightning strike protection system for fiber reinforced composites

A simulation-assisted additive manufacturing system and method for generating an anisotropic compensation to account for non-uniform deformation due to additive manufacturing and service loading. The predicted deformation may not be fully defined. The present disclosure provides a system and method for estimating the missing deformation data through regression analysis. The present disclosure also provides an integrated framework where the various simulated-assisted design modules are configured for two-way communication and sharing access to changes to the model.

System and method for simulation-assisted additive manufacturing involving estimating anisotropic deformation

Systems and methods for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.

Systems and methods for generating a molecular dynamic graded lattice structure and their application to additive manufacturing

Toolpath generation for additive manufacturing systems involves operations on polygonal contours derived from a model for additively manufacturing a structure. One aspect involves modifying or creating a model to allow parts to be printed without starting and stopping the printing equipment by generating continuous toolpaths or toolpaths having a reduced number of isolated paths. Another aspect involves modifying a slicing engine to generate a continuous toolpath or toolpath having a reduced number of isolated paths based on a representation of an object to be additively manufactured. Another aspect involves selectively placing the gaps at alternating positions among the sliced layers to create a zippering effect.

Continuous toolpaths for additive manufacturing

An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple layers during the build of 3D printing. The device includes a penetrating extension that fits within the void to create a vertical strengthening feature via heat and/or extruded fill material. The size and/or movement of the heated extension can impact the void side walls to reflow the build material and blend the layers together within the void side walls.

Penetrating and actuating nozzle for extrusion-based 3D printing

Systems and methods for generating graded lattice structures that can be used as infill for additively manufactured articles. Tailored sectioning and field-based smoothing are modified polygon, e.g., circle, packing algorithms that adjust the size of the circles based on physical field data to adapt the infill generation process to a field expected to be experienced by the article. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from tailored sectioning, field-based smoothing, and force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.

Systems and methods for generating a graded lattice structure and their application to additive manufacturing

A system and method for improving additive manufacturing, including additive manufacturing toolpaths, is provided. The system and method includes a toolpath generator that obtains initial toolpaths of an object, identifies isolated paths in the toolpaths, and adds bridge connections between neighboring isolated paths in each layer to improve the toolpaths. The bridge connections facilitate the continuous and non-stop deposition of each layer according to improved toolpaths during additive manufacture, which can reduce total deposition time and improve the resultant additive manufacture.

System and method for additive manufacturing with toolpath bridges and resultant structure

An improved method for obtaining high fiber volume fraction, long fiber injection molded articles is provided. According to one embodiment, the method includes forming an injection molding feedstock by cutting pre-impregnated fiber-reinforced tape into platelets. The platelets can be coated with a thin layer of polymer to allow sliding of the platelets with respect to each other at the early stages of plastication, rather than forcing relative motion of fibers with respect to each other. The method can further include the dispersion of material only in the final stages of the injection molding screw to promote gentle motion of the feedstock at the earlier stages of the plastication process. The method allows improvement of mechanical properties of articles manufactured with equipment and techniques that are prevalent in high volume automotive and consumer industries.

Long fiber injection molding

A structural health monitoring method is provided that utilizes self-sensing printed polymer structures. The method is based on resistivity properties of conductive materials, which can be integrated to a 3D printed polymer structure during additive manufacturing. An article to be monitored has at least one 3D printed polymer structure including a circuit comprising at least one conductive pathway extending through a non-conductive material. The resistance across the circuit is measured during or after loading of the article to determine a resistance value. The measured resistance value is compared to a known resistance value, and based on the comparison, a defect can be detected in the 3D printed polymer structure. Structural health monitoring systems and articles with integrated structural health monitoring are also provided.

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Knoxville, TN, United States of America

Seokpum Kim