Northrop Grumman Systems Corporation

Sung S Park

Eric G Barnes

Pedro A Gonzalez

Todd Lewis Szallay

Steven J Floyd

Brett G Morham

Cody J Brown

Reese R Allen

Ryan L Bischoff

Anthony M Tamayo

Pedro A Gonzales

A system for fabricating a composite part using a 3D printing machine. The system includes means for forming the part by depositing consecutive part layers each including rows of filaments made of a part material from the machine, where depositing each part layer includes non-sequentially depositing one set of a plurality of filaments so that a gap is formed between the filaments and then depositing any number of additional sets of filaments so that each adjacent pair of filaments in each additional set of filaments are non-sequentially deposited.

System for deposition and fabrication of 3D integrated composite structures

A method for fabricating a composite part using a 3D printing machine. The method includes forming a support structure by depositing consecutive support structure layers including rows of filaments made of a support structure material from the machine on a build plate, smoothing out a top surface of the support structure after it is formed, and forming the part by depositing consecutive part layers including rows of filaments made of a part material from the machine on the support structure.

Method for fabricating a 3D composite structure including smoothing of support structures

A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing consecutive part layers each including rows of filaments made of a part material from the machine, where depositing each part layer includes non-sequentially depositing one set of a plurality of filaments so that a gap is formed between the filaments and then depositing any number of additional sets of filaments so that each adjacent pair of filaments in each additional set of filaments are non-sequentially deposited.

Methods for deposition and fabrication of 3D integrated composite structures

A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing an alternating sequence of first part layers including rows of filaments made of a first part material and depositing second part layers including rows of filaments made of a second part material, where the second part material is different than the first part material and provides adhesion between the first part layers.

Method for fabricating multi-material structure for 3D integrated composite structures

A 3D printing machine for fabricating high performance 3D integrated composite structures, where the machine includes a robot having a base portion, a robot arm and a rotatable connector secured to the arm opposite to the base portion, at least one source of an extrudable material, and an end-effector mounted to the rotatable connector and including at least one extruder module for extruding the extrudable material. The extruder module includes a nozzle assembly for extruding heated material out of the end-effector, and the end-effector is rotatable relative to the structure by the rotatable connector so that the nozzle assembly can be oriented normal to the part in different orientations without significantly changing a pose of the robot.

Methods and apparatus for fabrication of 3D integrated composite structures

A printing machine for fabricating high performance 3D integrated composite structures. The machine includes a robot having a base portion, a robot arm and an end joint secured to the arm opposite to the base portion, at least one source of an extrudable material, and an end-effector mounted to the end joint. The end-effector includes at least one extruder module for extruding the extrudable material and a rotary assembly, where the extruder module includes a nozzle assembly for extruding heated material out of the end-effector. The extruder module is mounted to the rotary assembly and the rotary assembly is rotatable so as to rotate the nozzle assembly relative to the part without rotating the end-effector.

Printing machine for fabricating 3D integrated composite structures and having a rotatable extruder module

A printing machine for fabricating high performance 3D integrated composite structures, where the machine includes a robot having a base portion, a robot arm and an end joint secured to the arm opposite to the base portion, a plurality of sources of extrudable material, and an end-effector mounted to the end joint. The end-effector includes a multiple-extruder module having a first extruder and a second extruder each including a separate nozzle assembly, wherein the first extruder receives one extrudable material and the second extruder receives another extrudable material.

Printing machine for fabricating 3D integrated composite structures and having a multiple extruder module

A system is described for reinforcing a thermoplastic workpiece including a subject surface and an underlying workpiece body volume. At least one substantially linear Z-pin having proximal and distal pin ends longitudinally separated by a pin body is provided. The proximal pin end is in direct contact with the subject surface. An ultrasonic energy source applies ultrasonic energy to the Z-pin to ultrasonically heat the Z-pin and thus locally melt the workpiece material of the subject surface and/or the workpiece body to create a melted workpiece material. The proximal pin end and at least a portion of the pin body of the Z-pin are penetrated into the melted workpiece material to create an inserted Z-pin length. The inserted Z-pin length is maintained in the workpiece body volume by solidified melted workpiece material around the inserted Z-pin length to reinforce the workpiece. A method of reinforcing a workpiece is also provided.

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Rancho Palos Verdes, CA, United States of America

Sung S Park