Note: Descriptions are shown in the official language in which they were submitted.
SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING
CROSS-REFERENCE TO RELATED APPLICATIONS
This application relates to United States patent application no. 15/642,705
filed July 6,
2017, and to United States patent application no. 15/642,787 filed July 6,
2017.
FIELD
The present disclosure relates to additive manufacturing.
BACKGROUND
An additive manufacturing process may include dispensing or extruding a
feedstock
material from a print head, or nozzle, that is capable of moving in three
dimensions under
computer control to manufacture a part. Depending on the properties of the
feedstock
material, its advancement through the print head may be difficult or result in
undesirable
effects. For example, when the feedstock material is or includes a glutinous
material, the
feedstock material may gum-up, clog, or otherwise foul the print head. As
another example,
when the feedstock material includes elongate carbon or other fibers, the
fibers may kink,
break, or otherwise buckle and become damaged or clog the print head. As yet
another
example, when the feedstock material is or includes an uncured or partially
cured, curable
resin, the resin may undesirably gradually cure inside the print head to
progressively clog the
print head and partially or completely obstruct the operative advancement of
the feedstock
material through the print head.
SUMMARY
Accordingly, apparatuses and methods, intended to address at least the above-
identified concerns, would find utility.
The following is a non-exhaustive list of examples of the subject matter
according to
the present disclosure.
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Date Recue/Date Received 2021-08-11
One example of the subject matter according to the invention relates to a
system for
additively manufacturing an object. The system comprises a fiber supply, a
resin supply, a
rigidizing mechanism, a delivery guide, a feed mechanism, a de-rigidizing
mechanism, and a
curing mechanism. The fiber supply is configured to dispense the elongate
fibers. The resin
supply is configured to apply a resin to the elongate fibers, dispensed from
the fiber supply, to
create a feedstock line. The feedstock line comprises the elongate fibers, at
least partially
encapsulated in the resin, which is in a first non-rigid uncured state. The
rigidizing mechanism
is to receive the feedstock line with the resin in the first non-rigid uncured
state. The rigidizing
mechanism is configured to transform the resin of the feedstock line from the
first non-rigid
uncured state to a rigid uncured state. The feedstock line and the resin are
more rigid when
the resin is in the rigid uncured state than when the resin is in the first
non-rigid uncured state.
The delivery guide is to receive the feedstock line from the rigidizing
mechanism with the resin
in the rigid uncured state. The delivery guide is configured to deposit the
feedstock line along
a print path. The feed mechanism is configured to feed the feedstock line
through the delivery
guide. The de-rigidizing mechanism is configured to transform the resin of the
feedstock line,
as the feedstock line passes through the delivery guide or as the feedstock
line exits the
delivery guide, from the rigid uncured state to a second non-rigid uncured
state, so that, before
the feedstock line is deposited along the print path by the delivery guide,
the resin of the
feedstock line, exiting the delivery guide, is in the second non-rigid uncured
state. The
feedstock line and the resin are less rigid when the resin is in the second
non-rigid uncured
state than when the resin is in the rigid uncured state. The curing mechanism
is configured to
transform the resin of the feedstock line, deposited by the delivery guide
along the print path,
from the second non-rigid uncured state to an at least partially cured state.
The system therefore may be used to manufacture the object from a fiber
reinforced
composite material that is created from the resin and the elongate fibers
while the object is
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Date Recue/Date Received 2021-08-11
being manufactured. Moreover, the system may be used to manufacture the object
with the
elongate fibers being oriented in desired and/or predetermined orientations
throughout the
object, such as to define desired properties of the object. In addition,
because the resin is
uncured when applied to the elongate fibers to create the feedstock line, the
first non-rigid
uncured state of the feedstock line comprises the resin in a viscous
condition. If permitted to
remain in such a viscous, tacky, or sticky condition, the resin of the
feedstock line would be
difficult to handle by the system, and the feed mechanism and the delivery
guide thereof, for
example, gumming up or otherwise soiling component parts of the system.
Moreover, if the
resin were in such a viscous state, the elongate fibers may be caused to
buckle at the inlet to
or within the delivery guide. Accordingly, the rigidizing mechanism transforms
the feedstock
line from the first non-rigid uncured state to the rigid uncured state so that
the feed
mechanism can advance the feedstock line into the delivery guide without
soiling or
damaging the feed mechanism, and without the elongate fibers buckling,
breaking, or
otherwise becoming damaged. Moreover, because the feedstock line is then in
the rigid
uncured state, it will easily be advanced through the delivery guide for
ultimate depositing
along the print path to manufacture the object. However, the feedstock line in
its rigid
uncured state is too rigid for deposition along the print path in three-
dimensions.
Accordingly, the de-rigidizing mechanism is provided to transform the
feedstock line from
the rigid uncured state to a sufficiently non-rigid uncured state¨the second
non-rigid
uncured state¨for ultimate deposition along the print path. The de-rigidizing
mechanism
may de-rigidize the feedstock line either as it is passing through the
delivery guide or as the
feedstock line exits the delivery guide, depending on the configuration of the
de-rigidizing
mechanism and depending on the properties of the feedstock line in the second
non-rigid
uncured state. Finally, the curing mechanism transforms the resin from the
second non-rigid
uncured state to the at least partially cured state, to at least partially
cure the object while it
is being manufactured, or in situ.
Another example of the subject matter according to the invention relates to a
method of additively manufacturing an object. The method comprises applying a
resin in a
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first non-rigid uncured state to elongate fibers to create a feedstock line.
The feedstock line
comprises the elongate fibers at least partially encapsulated in the resin.
The method also
comprises transforming the resin of the feedstock line from the first non-
rigid uncured state
to a rigid uncured state. The feedstock line and the resin are more rigid when
the resin is in
the rigid uncured state than when the resin is in the first non-rigid uncured
state. The
method further comprises introducing the feedstock line into a delivery guide
with the resin
of the feedstock line in the rigid uncured state. The method additionally
comprises
transforming the resin of the feedstock line from the rigid uncured state to a
second non-
rigid uncured state as the feedstock line passes through the delivery guide or
as the
feedstock line exits the delivery guide. The feedstock line and the resin are
less rigid when
the resin is in the second non-rigid uncured state than when the resin is in
the rigid uncured
state. The method also comprises depositing the feedstock line along a print
path, with the
resin of the feedstock line in the second non-rigid uncured state, using the
delivery guide.
The method further comprises at least partially curing the resin of the
feedstock line after
the feedstock line is deposited by the delivery guide along the print path.
The method therefore may implemented to manufacture the object from a fiber
reinforced composite material that is created from the resin and the elongate
fibers while
the object is being manufactured. Moreover, the method may be implemented to
manufacture the object with the elongate fibers being oriented in desired
and/or
.. predetermined orientations throughout the object, such as to define desired
properties of
the object. In addition, because the resin is uncured when applied to the
elongate fibers to
create the feedstock line, the first non-rigid uncured state of the feedstock
line comprises the
resin in a viscous condition. If permitted to remain in such a viscous, tacky,
or sticky
condition, the resin of the feedstock line would be difficult to introduce
into the delivery
guide, for example, potentially gumming up the delivery guide or buckling,
kinking, or even
breaking the elongate fibers. Accordingly, transforming the resin to the rigid
uncured state
facilitates the introduction of the feedstock line into and the passage of the
feedstock line
through the delivery guide, without the elongate fibers buckling, breaking, or
otherwise
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becoming damaged, and without the resin soiling an associated system.
Subsequently
transforming the resin from the rigid uncured state to the second non-rigid
uncured state as
the feedstock line passes through the delivery guide or as the feedstock line
exits the delivery
guide results in the feedstock line being sufficiently flexible to operatively
be deposited in
.. three dimensions by the delivery guide to additively manufacture the
object. Depending on
the properties of the feedstock line, in some implementations of the method,
it may be
beneficial to transform the feedstock line to the second non-rigid cured state
as it passes
through the delivery guide. In other implementations of the method, it may be
beneficial to
transform the feedstock line to the second non-rigid uncured state as it exits
the delivery
.. guide. Finally, at least partially curing the resin from the second non-
rigid uncured state to
the at least partially cured state, enables curing of the object as it is
being manufactured, or
in situ.
Another example of the subject matter according to the invention relates to a
system
for additively manufacturing an object. The system comprises a source of a
feedstock line, a
rigidizing mechanism, a delivery guide, a feed mechanism, a de-rigidizing
mechanism, and a
curing mechanism. The feedstock line, originating from the source, comprises
elongate
fibers, at least partially encapsulated in a resin in a first at least
partially uncured state. The
rigidizing mechanism is to receive the feedstock line from the source with the
resin of the
feedstock line in the first at least partially uncured state. The rigidizing
mechanism is
configured to transform the resin of the feedstock line from the first at
least partially
uncured state to a rigid at least partially uncured state. The feedstock line
and the resin are
more rigid when the resin is in the rigid at least partially uncured state
than when the resin is
in the first at least partially uncured state. The delivery guide is to
receive the feedstock line
from the rigidizing mechanism with the resin in the rigid at least partially
uncured state. The
delivery guide is configured to deposit the feedstock line along a print path.
The feed
mechanism is configured to feed the feedstock line through the delivery guide.
The de-
rigidizing mechanism is configured to transform the resin of the feedstock
line, as the
feedstock line passes through the delivery guide or as the feedstock line
exits the delivery
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guide, from the rigid at least partially uncured state to a second at least
partially uncured
state, so that, before the feedstock line is deposited along the print path by
the delivery
guide, the resin of the feedstock line, exiting the delivery guide, is in the
second at least
partially uncured state. The feedstock line and the resin are less rigid when
the resin is in the
second at least partially uncured state than when the resin is in the rigid at
least partially
uncured state. The curing mechanism is configured to transform the resin of
the feedstock
line, deposited by the delivery guide along the print path, from the second at
least partially
uncured state to an at least partially cured state.
The system therefore may be used to manufacture the object from the feedstock
line.
Moreover, the system may be used to manufacture the object with the elongate
fibers being
oriented in desired and/or predetermined orientations throughout the object,
such as to
define desired properties of the object. Because the elongate fibers are
encapsulated in the
resin when the feedstock line is in the source, the feedstock line originating
from the source
may be described as a prepreg feedstock line. In addition, because the
feedstock line may
have a significant length, the feedstock line in the source may need to be
coiled, or spooled,
for the source to be compact or otherwise manageable in size. Accordingly, the
feedstock
line originating from the source may need to be sufficiently flexible, or
bendable, to be coiled
without damage to the elongate fibers, yet sufficiently rigid so that the
resin does not flow
and so that the feedstock line maintains its integrity as a continuous
flexible line. However,
the first at least partially uncured state of the feedstock line may be too
flexible to be
operably fed into and advanced through the delivery guide and may be too
tacky, or sticky,
to be operably handled by the system without gumming up, or otherwise soiling,
component
parts of the system. Accordingly, the rigidizing mechanism transforms the
feedstock line from
the first at least partially uncured state to the rigid at least partially
uncured state so that the
feed mechanism can advance the feedstock line into the delivery guide without
soiling or
damaging the feed mechanism, and without the elongate fibers buckling,
breaking, or
otherwise becoming damaged. Moreover, because the feedstock line is then in
the rigid at
least partially uncured state, it will easily be advanced through the delivery
guide for ultimate
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depositing along the print path to manufacture the object. However, the
feedstock line in its
rigid at least partially uncured state is too rigid for deposition along the
print path in three-
dimensions. Accordingly, the de-rigidizing mechanism is provided to transform
the feedstock
line from the rigid at least partially uncured state to a sufficiently non-
rigid uncured state-
the second at least partially uncured state¨for ultimate deposition along the
print path. The
de-rigidizing mechanism may de-rigidize the feedstock line either as it is
passing through the
delivery guide or as the feedstock line exits the delivery guide, depending on
the
configuration of the de-rigidizing mechanism and depending on the properties
of the
feedstock line in the second at least partially uncured state. Finally, the
curing mechanism
transforms the resin from the second at least partially uncured state to the
at least partially
cured state, to at least partially cure the object while it is being
manufactured, or in situ.
Another example of the subject matter according to the invention relates to a
method of additively manufacturing an object from a feedstock line, in which
the feedstock
line comprises elongate fibers at least partially encapsulated in a resin. The
method
comprises transforming the resin of the feedstock line from a first at least
partially uncured
state to a rigid at least partially uncured state. The feedstock line and the
resin are more rigid
when the resin is in the rigid at least partially uncured state than when the
resin is in the first
at least partially uncured state. The method further comprises introducing the
feedstock line
into a delivery guide with the resin of the feedstock line in the rigid at
least partially uncured
state. The method additionally comprises transforming the resin of the
feedstock line from
the rigid at least partially uncured state to a second at least partially
uncured state as the
feedstock line passes through the delivery guide or as the feedstock line
exits the delivery
guide. The feedstock line and the resin are less rigid when the resin is in
the second at least
partially uncured state than when the resin is in the rigid at least partially
uncured state. The
method further comprises depositing the feedstock line along a print path,
with the resin in
the second at least partially uncured state, using the delivery guide. The
method also
comprises transforming the resin of the feedstock line from the second at
least partially
uncured state to an at least partially cured state after the feedstock line is
dispensed from
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the delivery guide along the print path. The resin in the at least partially
cured state is cured
more than the resin in the second at least partially uncured state.
The method therefore may be implemented to manufacture the object from the
feedstock line. Moreover, the method may be implemented to manufacture the
object with
the elongate fibers being oriented in desired and/or predetermined
orientations throughout
the object, such as to define desired properties of the object. Because the
elongate fibers are
encapsulated in the resin, the feedstock line 106 may be described as a
prepreg feedstock
line. In addition, because the feedstock line may have a significant length,
the feedstock line
may be coiled, or spooled, prior to being introduced into the delivery guide.
Accordingly, the
feedstock line may need to be sufficiently flexible, or bendable, to be coiled
without damage
to the elongate fibers, yet sufficiently rigid so that the resin does not flow
and so that the
feedstock line maintains its integrity as a continuous flexible line. However,
the first at least
partially uncured state of the feedstock line may be too flexible to be
operably fed into and
advanced through the delivery guide and may be too tacky, or sticky, to be
operably handled
by an associated system without gumming up, or otherwise soiling, component
parts of the
system. Accordingly, transforming the feedstock line from the first at least
partially uncured
state to the rigid at least partially uncured state facilitates the
introduction of the feedstock
line into and the passage of the feedstock line through the delivery guide,
without the
elongate fibers buckling, breaking, or otherwise becoming damaged, and without
the resin
soiling an associated system. Subsequently transforming the feedstock line
from the rigid at
least partially uncured state to the second at least partially uncured state
as the feedstock
line passes through the delivery guide or as the feedstock line exits the
delivery guide results
in the feedstock line being sufficiently flexible to be operatively deposited
in three
dimensions by the delivery guide to additively manufacture the object.
Depending on the
properties of the feedstock line, in some implementations of the method, it
may be
beneficial to transform the feedstock line to the second non-rigid cured state
as it passes
through the delivery guide. In other implementations of the method, it may be
beneficial to
transform the feedstock line to the second non-rigid uncured state as it exits
the delivery
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guide. Finally, at least partially curing the resin from the second at least
partially uncured state
to the at least partially cured state, enables curing of the object as it is
being manufactured, or
in situ.
In one embodiment, there is provided a system for additively manufacturing an
object.
The system includes: a fiber supply, configured to dispense elongate fibers; a
resin supply,
configured to apply a resin to the elongate fibers dispensed from the fiber
supply, to create a
feedstock line including the elongate fibers at least partially encapsulated
in the resin, which
is in a first non-rigid uncured state; and a rigidizing mechanism to receive
the feedstock line
with the resin in the first non-rigid uncured state. The rigidizing mechanism
is configured to
transform the resin of the feedstock line from the first non-rigid uncured
state to a rigid
uncured state. The feedstock line and the resin are more rigid when the resin
is in the rigid
uncured state than when the resin is in the first non-rigid uncured state. The
system further
includes a delivery guide to receive the feedstock line from the rigidizing
mechanism with the
resin in the rigid uncured state. The delivery guide is configured to deposit
the feedstock line
along a print path. The system further includes: a feed mechanism, configured
to feed the
feedstock line through the delivery guide; and a de-rigidizing mechanism,
configured to
transform the resin of the feedstock line as the feedstock line passes through
the delivery
guide or as the feedstock line exits the delivery guide from the rigid uncured
state to a second
non-rigid uncured state, so that, before the feedstock line is deposited along
the print path by
the delivery guide, the resin of the feedstock line exiting the delivery guide
is in the second
non-rigid uncured state. The feedstock line and the resin are less rigid when
the resin is in the
second non-rigid uncured state than when the resin is in the rigid uncured
state. The system
further includes: a curing mechanism, configured to transform the resin of the
feedstock line
deposited by the delivery guide along the print path from the second non-rigid
uncured state
to an at least partially cured state; and a control system. The control system
includes at least
one sensor, configured to sense at least one physical characteristic
associated with the
feedstock line. The at least one physical characteristic is selected from
rigidity, stiffness,
flexibility, hardness, and viscosity. The control system is configured to
actively control in real
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Date Recue/Date Received 2021-08-11
time, based at least in part on the at least one physical characteristic
associated with the
feedstock line, (i) the rigidizing mechanism to control transformation of the
resin of the
feedstock line from the first non-rigid uncured state to the rigid uncured
state, and (ii) the feed
mechanism to control a feed rate of the feedstock line, collectively to ensure
that the feedstock
line is sufficiently flexible so that deposition of the feedstock line by the
delivery guide along
the print path may be performed operatively.
In another embodiment, there is provided a system for additively manufacturing
an
object. The system includes: a fiber supply, configured to dispense elongate
fibers; a resin
supply, configured to apply a resin to the elongate fibers dispensed from the
fiber supply, to
create a feedstock line including the elongate fibers at least partially
encapsulated in the resin,
which is in a first non-rigid uncured state; a rigidizing mechanism to receive
the feedstock line
with the resin in the first non-rigid uncured state. The rigidizing mechanism
is configured to
transform the resin of the feedstock line from the first non-rigid uncured
state to a rigid
uncured state. The feedstock line and the resin are more rigid when the resin
is in the rigid
uncured state than when the resin is in the first non-rigid uncured state. The
system further
includes a delivery guide to receive the feedstock line from the rigidizing
mechanism with the
resin in the rigid uncured state. The delivery guide is configured to deposit
the feedstock line
along a print path. The system further includes: a feed mechanism, configured
to feed the
feedstock line through the delivery guide; and a de-rigidizing mechanism,
configured to
transform the resin of the feedstock line as the feedstock line passes through
the delivery
guide or as the feedstock line exits the delivery guide from the rigid uncured
state to a second
non-rigid uncured state, so that, before the feedstock line is deposited along
the print path by
the delivery guide, the resin of the feedstock line exiting the delivery guide
is in the second
non-rigid uncured state. The feedstock line and the resin are less rigid when
the resin is in the
second non-rigid uncured state than when the resin is in the rigid uncured
state. The system
further includes: a curing mechanism, configured to transform the resin of the
feedstock line
deposited by the delivery guide along the print path from the second non-rigid
uncured state
to an at least partially cured state; and a control system. The control system
includes at least
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Date Recue/Date Received 2021-08-11
one sensor, configured to sense at least one physical characteristic
associated with the
feedstock line. The at least one physical characteristic is selected from
rigidity, stiffness,
flexibility, hardness, and viscosity. The control system is configured to
actively control in real
time, based at least in part on the at least one physical characteristic
associated with the
feedstock line, (i) the de-rigidizing mechanism to control transformation of
the resin of the
feedstock line from the rigid uncured state to the second non-rigid uncured
state as the
feedstock line passes through the delivery guide or as the feedstock line
exits the delivery
guide, and (ii) the feed mechanism to control a feed rate of the feedstock
line, collectively to
ensure that the feedstock line is sufficiently flexible so that deposition of
the feedstock line by
the delivery guide along the print path may be performed operatively.
In another embodiment, there is provided a system for additively manufacturing
an
object. The system including: a fiber supply, configured to dispense elongate
fibers below a
threshold temperature; a resin supply, configured to apply a resin in a first
non-rigid uncured
state to the elongate fibers dispensed from the fiber supply below the
threshold temperature,
to create a feedstock line including the elongate fibers at least partially
encapsulated in the
resin, with the resin being in a rigid uncured state as a result of the
elongate fibers being below
the threshold temperature; and a delivery guide to receive the feedstock line
with the resin in
the rigid uncured state. The delivery guide is configured to deposit the
feedstock line along a
print path. The system further includes a feed mechanism, configured to feed
the feedstock
line through the delivery guide, and a de-rigidizing mechanism, configured to
transform the
resin of the feedstock line as the feedstock line passes through the delivery
guide or as the
feedstock line exits the delivery guide, from the rigid uncured state to a
second non-rigid
uncured state, so that, before the feedstock line is deposited along the print
path by the
delivery guide, the resin of the feedstock line exiting the delivery guide is
in the second non-
rigid uncured state. The feedstock line and the resin are less rigid when the
resin is in the
second non-rigid uncured state than when the resin is in the rigid uncured
state. The system
further includes a curing mechanism, configured to transform the resin of the
feedstock line
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Date Recue/Date Received 2021-08-11
deposited by the delivery guide along the print path, from the second non-
rigid uncured state
to an at least partially cured state.
In another embodiment, there is provided a method of additively manufacturing
an
object. The method involves step of applying a resin in a first non-rigid
uncured state to
elongate fibers to create a feedstock line. The feedstock line includes the
elongate fibers at
least partially encapsulated in the resin. The method further involves step of
transforming the
resin of the feedstock line from the first non-rigid uncured state to a rigid
uncured state using
a rigidizing mechanism. The feedstock line and the resin are more rigid when
the resin is in the
rigid uncured state than when the resin is in the first non-rigid uncured
state. The resin of the
feedstock line is transformed to the rigid uncured state prior to the
feedstock line being pushed
into a delivery guide by a feed mechanism. The method further involves steps
of: introducing
the feedstock line into the delivery guide with the resin of the feedstock
line in the rigid
uncured state by pushing the feedstock line into the delivery guide by the
feed mechanism;
and transforming the resin of the feedstock line from the rigid uncured state
to a second non-
rigid uncured state using a de-rigidizing mechanism as the feedstock line
passes through the
delivery guide or as the feedstock line exits the delivery guide. The
feedstock line and the resin
are less rigid when the resin is in the second non-rigid uncured state than
when the resin is in
the rigid uncured state. The method further involves step of sensing at least
one physical
characteristic associated with the feedstock line within the delivery guide.
The at least one
physical characteristic is selected from rigidity, stiffness, flexibility,
hardness, and viscosity. The
method further involves steps of: responsive to the step of sensing the at
least one physical
characteristic associated with the feedstock line within the delivery guide,
actively controlling
in real time, (i) the rigidizing mechanism to control the step of transforming
the resin of the
feedstock line from the first non-rigid uncured state to the rigid uncured
state, and (ii) the feed
mechanism to control a feed rate of the feedstock line being pushed into the
delivery guide;
and depositing the feedstock line along a print path, with the resin of the
feedstock line in the
second non-rigid uncured state, using the delivery guide. The step of actively
controlling in real
time the rigidizing mechanism and the feed mechanism ensures that the
feedstock line is
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Date Recue/Date Received 2021-08-11
sufficiently flexible so that the step of depositing the feedstock line along
the print path using
the delivery guide may be performed operatively. The method further involves
step of at least
partially curing the resin of the feedstock line after the feedstock line is
deposited by the
delivery guide along the print path.
In another embodiment, there is provided a method of additively manufacturing
an
object. The method involves step of applying a resin in a first non-rigid
uncured state to
elongate fibers to create a feedstock line. The feedstock line includes the
elongate fibers at
least partially encapsulated in the resin. The method further involves step of
transforming the
resin of the feedstock line from the first non-rigid uncured state to a rigid
uncured state using
a rigidizing mechanism. The feedstock line and the resin are more rigid when
the resin is in the
rigid uncured state than when the resin is in the first non-rigid uncured
state. The resin of the
feedstock line is transformed to the rigid uncured state prior to the
feedstock line being pushed
into a delivery guide by a feed mechanism. The method further involves steps
of: introducing
the feedstock line into the delivery guide with the resin of the feedstock
line in the rigid
uncured state by pushing the feedstock line into the delivery guide using the
feed mechanism
and transforming the resin of the feedstock line from the rigid uncured state
to a second non-
rigid uncured state using a de-rigidizing mechanism as the feedstock line
passes through the
delivery guide or as the feedstock line exits the delivery guide. The
feedstock line and the resin
are less rigid when the resin is in the second non-rigid uncured state than
when the resin is in
the rigid uncured state. The method further involves step of sensing at least
one physical
characteristic associated with the feedstock line within the delivery guide.
The at least one
physical characteristic is selected from rigidity, stiffness, flexibility,
hardness, and viscosity. The
method further involves steps of: responsive to the step of sensing the at
least one physical
characteristic associated with the feedstock line within the delivery guide,
actively controlling
in real time, (i) the de-rigidizing mechanism to control the step of
transforming the resin of the
feedstock line from the rigid uncured state to the second non-rigid uncured
state as the
feedstock line passes through the delivery guide or as the feedstock line
exits the delivery
guide and (ii) the feed mechanism to control a feed rate of the feedstock line
being pushed
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Date Recue/Date Received 2021-08-11
into the delivery guide; and depositing the feedstock line along a print path,
with the resin of
the feedstock line in the second non-rigid uncured state, using the delivery
guide. The step of
actively controlling in real time the de-rigidizing mechanism and the feed
mechanism ensures
that the feedstock line is sufficiently flexible so that the step of
depositing the feedstock line
along the print path using the delivery guide may be performed operatively.
The method
further involves step of at least partially curing the resin of the feedstock
line after the
feedstock line is deposited by the delivery guide along the print path.
In another embodiment, there is provided a method of additively manufacturing
an
object. The method involves step of applying a resin in a first non-rigid
uncured state to
elongate fibers to create a feedstock line. The feedstock line includes the
elongate fibers at
least partially encapsulated in the resin. The method further involves step of
transforming the
resin of the feedstock line from the first non-rigid uncured state to a rigid
uncured state using
a rigidizing mechanism. The feedstock line and the resin are more rigid when
the resin is in the
rigid uncured state than when the resin is in the first non-rigid uncured
state. The resin of the
feedstock line is transformed to the rigid uncured state prior to the
feedstock line being pushed
into a delivery guide by a feed mechanism. The method further involves steps
of: introducing
the feedstock line into the delivery guide with the resin of the feedstock
line in the rigid
uncured state by pushing the feedstock line into the delivery guide using the
feed mechanism;
and transforming the resin of the feedstock line from the rigid uncured state
to a second non-
rigid uncured state using a de-rigidizing mechanism as the feedstock line
passes through the
delivery guide or as the feedstock line exits the delivery guide. The
feedstock line and the resin
are less rigid when the resin is in the second non-rigid uncured state than
when the resin is in
the rigid uncured state. The method further involves step of sensing at least
one physical
characteristic associated with the feedstock line within the delivery guide.
The at least one
physical characteristic is selected from rigidity, stiffness, flexibility,
hardness, and viscosity. The
method further involves steps of: responsive to the step of sensing the at
least one physical
characteristic associated with the feedstock line within the delivery guide,
actively controlling
in real time, (i) the rigidizing mechanism to control the step of transforming
the resin of the
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Date Recue/Date Received 2021-08-11
feedstock line from the first non-rigid uncured state to the rigid uncured
state, (ii) the de-
rigidizing mechanism to control the step of transforming the resin of the
feedstock line from
the rigid uncured state to the second non-rigid uncured state as the feedstock
line passes
through the delivery guide or as the feedstock line exits the delivery guide,
and (iii) the feed
mechanism to control a feed rate of the feedstock line being pushed into the
delivery guide;
and depositing the feedstock line along a print path, with the resin of the
feedstock line in the
second non-rigid uncured state, using the delivery guide. The step of actively
controlling in real
time the rigidizing mechanism, the de-rigidizing mechanism and the feed
mechanism ensures
that the feedstock line is sufficiently flexible so that the step of
depositing of the feedstock line
along the print path using the delivery guide may be performed operatively.
The method
further involves step of at least partially curing the resin of the feedstock
line after the
feedstock line is deposited by the delivery guide along the print path. The
step of at least
partially curing the resin of the feedstock line after the feedstock line is
deposited by the
delivery guide along the print path is actively controlled in real time,
responsive to the step of
sensing the at least one physical characteristic associated with the feedstock
line within the
delivery guide, to control a cure rate of the resin of the feedstock line
deposited by the delivery
guide along the print path.
In another embodiment, there is provided a system for additively manufacturing
an
object. The system includes a source of a feedstock line. The feedstock line
includes elongate
fibers at least partially encapsulated in a resin in a first at least
partially uncured state. The
system further includes a rigidizing mechanism to receive the feedstock line
from the source
with the resin of the feedstock line in the first at least partially uncured
state. The rigidizing
mechanism is configured to transform the resin of the feedstock line from the
first at least
partially uncured state to a rigid at least partially uncured state. The
feedstock line and the
resin are more rigid when the resin is in the rigid at least partially uncured
state than when the
resin is in the first at least partially uncured state. The system further
includes a delivery guide
to receive the feedstock line from the rigidizing mechanism with the resin in
the rigid at least
partially uncured state. The delivery guide is configured to deposit the
feedstock line along a
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Date Recue/Date Received 2021-08-11
print path. The system further includes: a feed mechanism, configured to feed
the feedstock
line through the delivery guide; and a de-rigidizing mechanism, configured to
transform the
resin of the feedstock line as the feedstock line passes through the delivery
guide or as the
feedstock line exits the delivery guide from the rigid at least partially
uncured state to a second
at least partially uncured state, so that, before the feedstock line is
deposited along the print
path by the delivery guide, the resin of the feedstock line exiting the
delivery guide is in the
second at least partially uncured state. The feedstock line and the resin are
less rigid when the
resin is in the second at least partially uncured state than when the resin is
in the rigid at least
partially uncured state. The system further includes: a curing mechanism,
configured to
transform the resin of the feedstock line deposited by the delivery guide
along the print path
from the second at least partially uncured state to an at least partially
cured state; and a
control system. The control system includes at least one sensor, configured to
sense at least
one physical characteristic associated with the feedstock line. The at least
one physical
characteristic is selected from rigidity, stiffness, flexibility, hardness,
and viscosity. The control
system is configured to actively control in real time, based at least in part
on the at least one
physical characteristic associated with the feedstock line, (i) the rigidizing
mechanism to
control transformation of the resin of the feedstock line from the first at
least partially uncured
state to the rigid at least partially uncured state, and (ii) the feed
mechanism to control a feed
rate of the feedstock line, collectively to ensure that the feedstock line is
sufficiently flexible
so that deposition of the feedstock line by the delivery guide along the print
path may be
performed operatively.
In another embodiment, there is provided a system for additively manufacturing
an
object. The system includes a source of a feedstock line. The feedstock line
includes elongate
fibers at least partially encapsulated in a resin in a first at least
partially uncured state. The
system further includes a rigidizing mechanism to receive the feedstock line
from the source
with the resin of the feedstock line in the first at least partially uncured
state. The rigidizing
mechanism is configured to transform the resin of the feedstock line from the
first at least
partially uncured state to a rigid at least partially uncured state. The
feedstock line and the
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Date Recue/Date Received 2021-08-11
resin are more rigid when the resin is in the rigid at least partially uncured
state than when the
resin is in the first at least partially uncured state. The system further
includes a delivery guide
to receive the feedstock line from the rigidizing mechanism with the resin in
the rigid at least
partially uncured state. The delivery guide is configured to deposit the
feedstock line along a
print path. The system further includes: a feed mechanism, configured to feed
the feedstock
line through the delivery guide; and a de-rigidizing mechanism, configured to
transform the
resin of the feedstock line as the feedstock line passes through the delivery
guide or as the
feedstock line exits the delivery guide from the rigid at least partially
uncured state to a second
at least partially uncured state, so that, before the feedstock line is
deposited along the print
path by the delivery guide, the resin of the feedstock line exiting the
delivery guide is in the
second at least partially uncured state. The feedstock line and the resin are
less rigid when the
resin is in the second at least partially uncured state than when the resin is
in the rigid at least
partially uncured state. The system further includes: a curing mechanism,
configured to
transform the resin of the feedstock line deposited by the delivery guide
along the print path
from the second at least partially uncured state to an at least partially
cured state; and a
control system. The control system includes at least one sensor, configured to
sense at least
one physical characteristic associated with the feedstock line. The at least
one physical
characteristic is selected from rigidity, stiffness, flexibility, hardness,
and viscosity. The control
system is configured to actively control in real time, based at least in part
on the at least one
physical characteristic associated with the feedstock line, (i) the de-
rigidizing mechanism to
control transformation of the resin of the feedstock line from the rigid at
least partially uncured
state to the second at least partially uncured state, and (ii) the feed
mechanism to control a
feed rate of the feedstock line, collectively to ensure that the feedstock
line is sufficiently
flexible so that deposition of the feedstock line by the delivery guide along
the print path may
be performed operatively.
In another embodiment, there is provided a system for additively manufacturing
an
object. The system includes a source of a feedstock line. The feedstock line
includes elongate
fibers at least partially encapsulated in a resin in a first at least
partially uncured state. The
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Date Recue/Date Received 2021-08-11
system further includes a rigidizing mechanism to receive the feedstock line
from the source
with the resin of the feedstock line in the first at least partially uncured
state. The rigidizing
mechanism is configured to transform the resin of the feedstock line from the
first at least
partially uncured state to a rigid at least partially uncured state. The
feedstock line and the
resin are more rigid when the resin is in the rigid at least partially uncured
state than when the
resin is in the first at least partially uncured state. The system further
includes a delivery guide
to receive the feedstock line from the rigidizing mechanism with the resin in
the rigid at least
partially uncured state. The delivery guide is configured to deposit the
feedstock line along a
print path. The system further includes: a feed mechanism, configured to feed
the feedstock
line through the delivery guide; and a de-rigidizing mechanism, configured to
transform the
resin of the feedstock line as the feedstock line passes through the delivery
guide or as the
feedstock line exits the delivery guide from the rigid at least partially
uncured state to a second
at least partially uncured state, so that, before the feedstock line is
deposited along the print
path by the delivery guide, the resin of the feedstock line exiting the
delivery guide is in the
second at least partially uncured state. The feedstock line and the resin are
less rigid when the
resin is in the second at least partially uncured state than when the resin is
in the rigid at least
partially uncured state. The system further includes a curing mechanism,
configured to
transform the resin of the feedstock line deposited by the delivery guide
along the print path
from the second at least partially uncured state to an at least partially
cured state, and a
control system. The control system includes at least one sensor configured to
sense at least
one physical characteristic associated with the feedstock line. The at least
one physical
characteristic is selected from rigidity, stiffness, flexibility, hardness,
and viscosity. The control
system is configured to actively control in real time, based at least in part
on the at least one
physical characteristic associated with the feedstock line, (i) the rigidizing
mechanism to
control transformation of the resin of the feedstock line from the first at
least partially uncured
state to the rigid at least partially uncured state, and (ii) the de-
rigidizing mechanism to control
transformation of the resin of the feedstock line from the rigid at least
partially uncured state
to the second at least partially uncured state, collectively to ensure that
the feedstock line is
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Date Recue/Date Received 2021-08-11
sufficiently flexible so that deposition of the feedstock line by the delivery
guide along the print
path may be performed operatively.
In another embodiment, there is provided a method of additively manufacturing
an
object from a feedstock line, the feedstock line including elongate fibers at
least partially
encapsulated in a resin. The method involves step of transforming the resin of
the feedstock
line from a first at least partially uncured state to a rigid at least
partially uncured state using
a rigidizing mechanism. The feedstock line and the resin are more rigid when
the resin is in the
rigid at least partially uncured state than when the resin is in the first at
least partially uncured
state. The resin of the feedstock line is transformed to the rigid at least
partially uncured state
prior to the feedstock line being pushed into a delivery guide by a feed
mechanism. The
method further involves steps of introducing the feedstock line into the
delivery guide with
the resin of the feedstock line in the rigid at least partially uncured state
by pushing the
feedstock line into the delivery guide using the feed mechanism and
transforming the resin of
the feedstock line from the rigid at least partially uncured state to a second
at least partially
uncured state using a de-rigidizing mechanism as the feedstock line passes
through the
delivery guide or as the feedstock line exits the delivery guide. The
feedstock line and the resin
are less rigid when the resin is in the second at least partially uncured
state than when the
resin is in the rigid at least partially uncured state. The method further
involves step of sensing
at least one physical characteristic associated with the feedstock line within
the delivery guide.
The at least one physical characteristic is selected from rigidity, stiffness,
flexibility, hardness,
and viscosity. The method further involves steps of: responsive to the step of
sensing the at
least one physical characteristic associated with the feedstock line within
the delivery guide,
actively controlling in real time, (i) the rigidizing mechanism to control the
step of transforming
the resin of the feedstock line from the first at least partially uncured
state to the rigid at least
partially uncured state, and (ii) the feed mechanism to control a feed rate of
the feedstock line
being pushed into the delivery guide; and with the resin in the second at
least partially uncured
state, depositing the feedstock line along a print path using the delivery
guide. The step of
actively controlling in real time the rigidizing mechanism and the feed
mechanism ensures that
8k
Date Recue/Date Received 2021-08-11
the feedstock line is sufficiently flexible so that the step of depositing of
the feedstock line
along the print path using the delivery guide may be performed operatively.
The method
further involves step of transforming the resin of the feedstock line from the
second at least
partially uncured state to an at least partially cured state after the
feedstock line is deposited
by the delivery guide along the print path. The resin in the at least
partially cured state is cured
more than the resin in the second at least partially uncured state.
In another embodiment, there is provided a method of additively manufacturing
an
object from a feedstock line, the feedstock line including elongate fibers at
least partially
encapsulated in a resin. The method involves step of transforming the resin of
the feedstock
line from a first at least partially uncured state to a rigid at least
partially uncured state using
a rigidizing mechanism. The feedstock line and the resin are more rigid when
the resin is in the
rigid at least partially uncured state than when the resin is in the first at
least partially uncured
state. The resin of the feedstock line is transformed to the rigid at least
partially uncured state
prior to the feedstock line being pushed into a delivery guide by a feed
mechanism. The
.. method further involves steps of introducing the feedstock line into the
delivery guide with
the resin of the feedstock line in the rigid at least partially uncured state
by pushing the
feedstock line into the delivery guide using the feed mechanism and
transforming the resin of
the feedstock line from the rigid at least partially uncured state to a second
at least partially
uncured state using a de-rigidizing mechanism as the feedstock line passes
through the
.. delivery guide or as the feedstock line exits the delivery guide. The
feedstock line and the resin
are less rigid when the resin is in the second at least partially uncured
state than when the
resin is in the rigid at least partially uncured state. The method further
involves steps of:
sensing at least one physical characteristic associated with the feedstock
line within the
delivery guide, the at least one physical characteristic being selected from
rigidity, stiffness,
flexibility, hardness, and viscosity; and responsive to the step of sensing
the at least one
physical characteristic associated with the feedstock line within the delivery
guide, actively
controlling in real time, (i) the de-rigidizing mechanism to control the step
of transforming the
resin of the feedstock line from the rigid at least partially uncured state to
the second at least
81
Date Recue/Date Received 2021-08-11
partially uncured state, and (ii) the feed mechanism to control a feed rate of
the feedstock line
being pushed into the delivery guide. The method further involves step of,
with the resin in
the second at least partially uncured state, depositing the feedstock line
along a print path
using the delivery guide. The step of actively controlling in real time the de-
rigidizing
mechanism and the feed mechanism ensures that the feedstock line is
sufficiently flexible so
that the step of depositing the feedstock line along the print path using the
delivery guide may
be performed operatively. The method further involves step of transforming the
resin of the
feedstock line from the second at least partially uncured state to an at least
partially cured
state after the feedstock line is deposited by the delivery guide along the
print path. The resin
in the at least partially cured state is cured more than the resin in the
second at least partially
uncured state.
In another embodiment, there is provided a method of additively manufacturing
an
object from a feedstock line, the feedstock line including elongate fibers at
least partially
encapsulated in a resin. The method involves step of transforming the resin of
the feedstock
line from a first at least partially uncured state to a rigid at least
partially uncured state using
a rigidizing mechanism. The feedstock line and the resin are more rigid when
the resin is in the
rigid at least partially uncured state than when the resin is in the first at
least partially uncured
state. The resin of the feedstock line is transformed to the rigid at least
partially uncured state
prior to the feedstock line being pushed into a delivery guide by a feed
mechanism. The
method further involves steps of introducing the feedstock line into the
delivery guide with
the resin of the feedstock line in the rigid at least partially uncured state
by pushing the
feedstock line into the delivery guide using the feed mechanism and
transforming the resin of
the feedstock line from the rigid at least partially uncured state to a second
at least partially
uncured state using a de-rigidizing mechanism as the feedstock line passes
through the
delivery guide or as the feedstock line exits the delivery guide. The
feedstock line and the resin
are less rigid when the resin is in the second at least partially uncured
state than when the
resin is in the rigid at least partially uncured state. The method further
involves step of sensing
at least one physical characteristic associated with the feedstock line within
the delivery guide.
8m
Date Recue/Date Received 2021-08-11
The at least one physical characteristic is selected from rigidity, stiffness,
flexibility, hardness,
and viscosity. The method further involves step of, responsive to the step of
sensing the at
least one physical characteristic associated with the feedstock line within
the delivery guide,
actively controlling in real time, (i) the rigidizing mechanism to control the
step of transforming
the resin of the feedstock line from the first at least partially uncured
state to the rigid at least
partially uncured state, (ii) the de-rigidizing mechanism to control the step
of transforming the
resin of the feedstock line from the rigid at least partially uncured state to
the second at least
partially uncured state, and (iii) the feed mechanism to control a feed rate
of the feedstock
line being pushed into the delivery guide. The method further involves step
of, with the resin
in the second at least partially uncured state, depositing the feedstock line
along a print path
using the delivery guide. The step of actively controlling in real time the
rigidizing mechanism,
the de-rigidizing mechanism, and the feed mechanism ensures that the feedstock
line is
sufficiently flexible so that the step of depositing of the feedstock line
along the print path
using the delivery guide may be performed operatively. The method further
involves step of
transforming the resin of the feedstock line from the second at least
partially uncured state to
an at least partially cured state after the feedstock line is deposited by the
delivery guide along
the print path. The resin in the at least partially cured state is cured more
than the resin in the
second at least partially uncured state. The step of transforming the resin of
the feedstock line
from the second at least partially uncured state to the at least partially
cured state, after the
feedstock line is deposited by the delivery guide along the print path, is
actively controlled in
real time, responsive to the step of sensing the at least one physical
characteristic associated
with the feedstock line within the delivery guide, to control a cure rate of
the resin of the
feedstock line deposited by the delivery guide along the print path.
8n
Date Recue/Date Received 2021-08-11
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described one or more examples of the disclosure in general terms,
reference will now be made to the accompanying drawings, which are not
necessarily drawn
to scale, and wherein like reference characters designate the same or similar
parts throughout
the several views, and wherein:
Fig. 1 is a block diagram of a system for additively manufacturing an object,
according
to one or more examples of the present disclosure;
Fig. 2 is a schematic representation of the system of Fig. 1, according to one
or more
examples of the present disclosure;
Fig. 3 is a flow diagram of a method of additively manufacturing an object,
according
to one or more examples of the present disclosure;
Fig. 4 is a flow diagram of aircraft production and service methodology; and
Fig. 5 is a schematic illustration of an aircraft.
Fig. 6 is a block diagram of a system for additively manufacturing an object,
according
to one or more examples of the present disclosure;
Fig. 7 is a schematic representation of the system of Fig. 6, according to one
or more
examples of the present disclosure;
Fig. 8 is a flow diagram of a method of additively manufacturing an object,
according
to one or more examples of the present disclosure;
Fig. 9 is a flow diagram of aircraft production and service methodology; and
Fig. 10 is a schematic illustration of an aircraft.
9
Date Recue/Date Received 2021-08-11
DESCRIPTION
In Fig. 1, referred to above, solid lines, if any, connecting various elements
and/or
components may represent mechanical, electrical, fluid, optical,
electromagnetic and other
couplings and/or combinations thereof. As used herein, "coupled" means
associated directly
as well as indirectly. For example, a member A may be directly associated with
a member B,
or may be indirectly associated therewith, e.g., via another member C. It will
be understood
that not all relationships among the various disclosed elements are
necessarily represented.
Accordingly, couplings other than those depicted in the block diagrams may
also exist.
Dashed lines, if any, connecting blocks designating the various elements
and/or components
represent couplings similar in function and purpose to those represented by
solid lines;
however, couplings represented by the dashed lines may either be selectively
provided or
may relate to alternative examples of the present disclosure. Likewise,
elements and/or
components, if any, represented with dashed lines, indicate alternative
examples of the
present disclosure. One or more elements shown in solid and/or dashed lines
may be
omitted from a particular example without departing from the scope of the
present
disclosure. Environmental elements, if any, are represented with dotted lines.
Virtual
(imaginary) elements may also be shown for clarity. Those skilled in the art
will appreciate
that some of the features illustrated in Fig. 1 may be combined in various
ways without the
need to include other features described in Fig. 1, other drawing figures,
and/or the
accompanying disclosure, even though such combination or combinations are not
explicitly
illustrated herein. Similarly, additional features not limited to the examples
presented, may
be combined with some or all of the features shown and described herein.
In Figs. 3 and 4, referred to above, the blocks may represent operations
and/or
portions thereof and lines connecting the various blocks do not imply any
particular order or
dependency of the operations or portions thereof. Blocks represented by dashed
lines
indicate alternative operations and/or portions thereof. Dashed lines, if any,
connecting the
various blocks represent alternative dependencies of the operations or
portions thereof. It
will be understood that not all dependencies among the various disclosed
operations are
CA 3002479 2018-04-23
necessarily represented. Figs. 3 and 4 and the accompanying disclosure
describing the
operations of the method(s) set forth herein should not be interpreted as
necessarily
determining a sequence in which the operations are to be performed. Rather,
although one
illustrative order is indicated, it is to be understood that the sequence of
the operations may
be modified when appropriate. Accordingly, certain operations may be performed
in a
different order or simultaneously. Additionally, those skilled in the art will
appreciate that
not all operations described need be performed.
In the following description, numerous specific details are set forth to
provide a
thorough understanding of the disclosed concepts, which may be practiced
without some or
all of these particulars. In other instances, details of known devices and/or
processes have
been omitted to avoid unnecessarily obscuring the disclosure. While some
concepts will be
described in conjunction with specific examples, it will be understood that
these examples
are not intended to be limiting.
Unless otherwise indicated, the terms "first," "second," etc. are used herein
merely as
labels, and are not intended to impose ordinal, positional, or hierarchical
requirements on
the items to which these terms refer. Moreover, reference to, e.g., a "second"
item does not
require or preclude the existence of, e.g., a "first" or lower-numbered item,
and/or, e.g., a
"third" or higher-numbered item.
Reference herein to "one example" means that one or more feature, structure,
or
characteristic described in connection with the example is included in at
least one
implementation. The phrase "one example" in various places in the
specification may or may
not be referring to the same example.
As used herein, a system, apparatus, structure, article, element, component,
or
hardware "configured to" perform a specified function is indeed capable of
performing the
specified function without any alteration, rather than merely having potential
to perform the
specified function after further modification. In other words, the system,
apparatus,
structure, article, element, component, or hardware "configured to" perform a
specified
function is specifically selected, created, implemented, utilized, programmed,
and/or
11
CA 3002479 2018-04-23
designed for the purpose of performing the specified function. As used herein,
"configured to"
denotes existing characteristics of a system, apparatus, structure, article,
element,
component, or hardware which enable the system, apparatus, structure, article,
element,
component, or hardware to perform the specified function without further
modification. For
purposes of this disclosure, a system, apparatus, structure, article, element,
component, or
hardware described as being "configured to" perform a particular function may
additionally or
alternatively be described as being "adapted to" and/or as being "operative
to" perform that
function.
Illustrative, non-exhaustive examples of the subject matter according the
present
disclosure are provided below.
Referring generally to Fig. 1 and particularly to Fig. 2, system 100 for
additively
manufacturing object 102 is disclosed. System 100 comprises fiber supply 122,
resin
supply 124, rigidizing mechanism 112, delivery guide 116, feed mechanism 126,
de-rigidizing
mechanism 118, and curing mechanism 120. Fiber supply 122 is configured to
dispense
elongate fibers 108. Resin supply 124 is configured to apply resin 110 to
elongate fibers 108,
dispensed from fiber supply 122, to create feedstock line 106. Feedstock line
106 comprises
elongate fibers 108, at least partially encapsulated in resin 110, which is in
a first non-rigid
uncured state. Rigidizing mechanism 112 is to receive feedstock line 106 with
resin 110 in the
first non-rigid uncured state. Rigidizing mechanism 112 is configured to
transform resin 110 of
feedstock line 106 from the first non-rigid uncured state to a rigid uncured
state. Feedstock
line 106 and resin 110 are more rigid when resin 110 is in the rigid uncured
state than when
resin 110 is in the first non-rigid uncured state. Delivery guide 116 is to
receive feedstock line
106 from rigidizing mechanism 112 with resin 110 in the rigid uncured state.
Delivery guide
116 is configured to deposit feedstock line 106 along print path 114. Feed
mechanism 126 is
configured to feed feedstock line 106 through delivery guide 116. De-
rigidizing mechanism 118
is configured to transform resin 110 of feedstock line 106, as feedstock line
106 passes through
delivery guide 116 or as feedstock line 106 exits delivery guide 116, from the
rigid uncured
state to a second non-rigid uncured state, so that, before
12
Date Recue/Date Received 2021-08-11
feedstock line 106 is deposited along print path 114 by delivery guide 116,
resin 110 of
feedstock line 106, exiting delivery guide 116, is in the second non-rigid
uncured state.
Feedstock line 106 and resin 110 are less rigid when resin 110 is in the
second non-rigid
uncured state than when resin 110 is in the rigid uncured state. Curing
mechanism 120 is
configured to transform resin 110 of feedstock line 106, deposited by delivery
guide 116
along print path 114, from the second non-rigid uncured state to an at least
partially cured
state. The preceding subject matter of this paragraph characterizes example 1
of the present
disclosure.
System 100 therefore may be used to manufacture object 102 from a fiber
reinforced
.. composite material that is created from resin 110 and elongate fibers 108
while object 102 is
being manufactured. Moreover, system 100 may be used to manufacture object 102
with
elongate fibers 108 being oriented in desired and/or predetermined
orientations throughout
object 102, such as to define desired properties of object 102. In addition,
because resin 110
is uncured when applied to elongate fibers 108 to create feedstock line 106,
the first non-
rigid uncured state of feedstock line 106 comprises resin 110 in a viscous
condition. If
permitted to remain in such a viscous, tacky, or sticky condition, resin 110
of feedstock
line 106 would be difficult to handle by system 100, and feed mechanism 126
and delivery
guide 116 thereof, for example, gumming up or otherwise soiling component
parts of
system 100. Moreover, if resin 110 were in such a viscous state, elongate
fibers 108 may be
caused to buckle at the inlet to or within delivery guide 116. Accordingly,
rigidizing
mechanism 112 transforms feedstock line 106 from the first non-rigid uncured
state to the
rigid uncured state so that feed mechanism 126 can advance feedstock line 106
into delivery
guide 116 without soiling or damaging feed mechanism 126, and without elongate
fibers 108
buckling, breaking, or otherwise becoming damaged. Moreover, because feedstock
line 106
is then in the rigid uncured state, it will easily be advanced through
delivery guide 116 for
ultimate depositing along print path 114 to manufacture object 102. However,
feedstock
line 106 in its rigid uncured state is too rigid for deposition along print
path 114 in three-
dimensions. Accordingly, de-rigidizing mechanism 118 is provided to transform
feedstock
13
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line 106 from the rigid uncured state to a sufficiently non-rigid uncured
state¨the second
non-rigid uncured state¨for ultimate deposition along print path 114.
Moreover, de-
rigidizing mechanism 118 ensures appropriate wetting, or adhesion, between two
adjacent
layers of feedstock line 106, when a length of feedstock line 106 is being
deposited against a
prior-deposited length of feedstock line 106. De-rigidizing mechanism 118 may
de-rigidize
feedstock line 106 either as it is passing through delivery guide 116 or as
feedstock line 106
exits delivery guide 116, depending on the configuration of de-rigidizing
mechanism 118 and
depending on the properties of feedstock line 106 in the second non-rigid
uncured state.
Finally, curing mechanism 120 transforms resin 110 from the second non-rigid
uncured state
.. to the at least partially cured state, to at least partially cure object
102 while it is being
manufactured, or in situ.
Some examples of system 100 additionally or alternatively may be described as
3-D
printers.
Elongate fibers 108 may take any suitable form and be constructed of any
suitable
material depending on desired properties of object 102 to be manufactured by
system 100.
In one example, elongate fibers 108 include, but are not limited, to carbon
fibers, glass fibers,
synthetic organic fibers, aramid fibers, natural fibers, wood fibers, boron
fibers, silicon-
carbide fibers, optical fibers, fiber bundles, fiber tows, fiber weaves, fiber
braids, wires, metal
wires, conductive wires, and wire bundles. Feedstock line 106 may be created
from a single
configuration, or type, of elongate fibers 108 or may be created from more
than one
configuration, or type, of elongate fibers 108. By "elongate," it is meant
that elongate
fibers 108 are generally continuous in nature along feedstock line 106 as it
is being created,
as opposed to, for example, use of chopped-fiber segments. That said, elongate
fibers 108
may comprise discontinuous segments of fibers that are bundled, woven,
braided, or
.. otherwise combined, and still be considered generally continuous in nature
along feedstock
line 106. Elongate fibers 108 have a length that is significantly longer than
a dimension (e.g.,
diameter or width) that is transverse, or perpendicular, to its length. As an
illustrative, non-
exclusive example, elongate fibers 108 may have a length that is at least 100,
at least 1000,
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at least 10000, at least 100000, or at least 1000000 times greater than their
diameter or
width.
Resin 110 may take any suitable form depending on desired properties of object
102
and depending on the functionality of system 100 and curing mechanism 120. In
some
examples, resin 110 may comprise a photopolymer resin that is configured to be
cured by
selective application of light. In other examples, resin 110 may comprise a
thermoset resin
that is configured to be cured by selective application of heat or radiation.
Other types of
resin 110 also may be used and incorporated into system 100.
Referring generally to Fig. 1 and particularly to Fig. 2, feedstock line 106
in the first
non-rigid uncured state has a shear modulus less than or equal to 0.1 GPa.
Feedstock line 106
in the rigid uncured state has a shear modulus greater than 0.1 GPa. Feedstock
line 106 in
the second non-rigid uncured state has a shear modulus less than or equal to
0.1 GPa. The
preceding subject matter of this paragraph characterizes example 2 of the
present disclosure,
wherein example 2 also includes the subject matter according to example 1,
above.
With 0.1 GPa as a threshold shear modulus, or rigidity, feedstock line 106,
when
rigidized by rigidizing mechanism 112, is sufficiently rigid to be advanced by
feed
mechanism 126 into and through delivery guide 116. Moreover, by de-rigidizing
feedstock
line 106 below a shear modulus of 0.1 GPa, feedstock line 106 may be deposited
along a
circuitous print path, e.g., print path 114 with curves in two or three
dimensions. However,
other threshold values of shear modulus may be utilized, such as based on the
stiffness of
elongate fibers 108, the number of elongate fibers 108 in a corresponding tow,
a shape of
feedstock line 106, a diameter of feedstock line 106, properties of resin 110,
etc.
Referring generally to Fig. 1 and particularly to Fig. 2, rigidizing mechanism
112 is
configured to withdraw heat from resin 110 of feedstock line 106 in the first
non-rigid
uncured state to transform resin 110 of feedstock line 106 from the first non-
rigid uncured
state to the rigid uncured state. De-rigidizing mechanism 118 is configured to
heat resin 110
of feedstock line 106 in the rigid uncured state to transform resin 110 of
feedstock line 106
from the rigid uncured state to the second non-rigid uncured state. The
preceding subject
CA 3002479 2018-04-23
matter of this paragraph characterizes example 3 of the present disclosure,
wherein
example 3 also includes the subject matter according to example 1 or 2, above.
When rigidizing mechanism 112 withdraws heat from resin 110 of feedstock line
106
to transform it to the rigid uncured state, rigidizing mechanism 112 cools
resin 110 to a
sufficient degree that its shear modulus, or rigidity, is sufficiently high
for feed
mechanism 126 to operatively advance feedstock line 106 into and through
delivery
guide 116 without undesirably soiling, gumming up, or damaging feed mechanism
126 and
delivery guide 116. In some examples, rigidizing mechanism 112 may be
described as freezing
resin 110 and/or feedstock line 106. Then, to reverse the rigidity of resin
110 and feedstock
line 106, de-rigidizing mechanism 118 heats resin 110 to transform it to the
second non-rigid
uncured state for operative deposition by delivery guide 116 along print path
114.
Rigidizing mechanism 112 and de-rigidizing mechanism 118 may take any suitable
configuration and utilize any suitable mechanism for withdrawing heat and
applying heat,
respectively. For example, rigidizing mechanism 112 may utilize a
refrigeration cycle to
withdraw heat from resin 110. Additionally or alternatively, rigidizing
mechanism 112 may
utilize a cold fluid that is passed over and contacts feedstock line 106 to
withdraw heat from
resin 110. In some examples, de-rigidizing mechanism 118 may be or include a
resistive
heater, an inductive heater, or a radiative heater, such as operatively
coupled to or
positioned within delivery guide 116, such as at or adjacent to where
feedstock line 106 exits
delivery guide 116. Additionally or alternatively, de-rigidizing mechanism 118
may include or
utilize a laser or a heated fluid stream to heat resin 110. In some examples,
curing
mechanism 120 may additionally serve as de-rigidizing mechanism 118. Other
examples of
rigidizing mechanism 112 and de-rigidizing mechanism 118 also are within the
scope of the
present disclosure and may be incorporated into system 100.
Referring generally to Fig. 1 and particularly to Fig. 2, feed mechanism 126
is
configured to push feedstock line 106 through delivery guide 116. The
preceding subject
matter of this paragraph characterizes example 4 of the present disclosure,
wherein
example 4 also includes the subject matter according to any one of examples 1
to 3, above.
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Feed mechanism 126 facilitates the advancement of feedstock line 106 into,
through,
and out of delivery guide 116. By being positioned to push feedstock line 106
though delivery
guide 116, it is upstream of the exit of delivery guide 116 and thus is
positioned out of the
way of the movement of delivery guide 116 and deposition of feedstock line 106
along print
path 114.
Referring generally to Fig. 1 and particularly to Fig. 2, feed mechanism 126
comprises
opposing rollers or belts 128, configured to engage opposite sides of
feedstock line 106 and
to selectively rotate to push feedstock line 106 through delivery guide 116.
The preceding
subject matter of this paragraph characterizes example 5 of the present
disclosure, wherein
.. example 5 also includes the subject matter according to example 4, above.
Opposing rollers or belts 128, when selectively rotated, act to frictionally
engage
feedstock line 106, thereby feeding it between opposing rollers or belts 128
and pushing it
into and through delivery guide 116. Feed mechanism 126 additionally or
alternatively may
comprise other pinch mechanisms configured to push feedstock line 106 through
delivery
guide 116.
Referring generally to Fig. 1 and particularly to Fig. 2, system 100 further
comprises
control system 130 that comprises at least one sensor 132, configured to sense
at least one
physical characteristic associated with feedstock line 106. Control system 130
is configured to
actively control at least one of rigidizing mechanism 112, feed mechanism 126,
de-rigidizing
mechanism 118, or curing mechanism 120, based at least in part on at least the
one physical
characteristic associated with feedstock line 106. The preceding subject
matter of this
paragraph characterizes example 6 of the present disclosure, wherein example 6
also
includes the subject matter according to any one of examples 1 to 5, above.
By sensing at least one physical characteristic associated with feedstock line
106 and
actively controlling rigidizing mechanism 112, feed mechanism 126, de-
rigidizing
mechanism 118, and/or curing mechanism 120 based on at least one physical
characteristic
associated with feedstock line 106, system 100 may in real time control the
rigidity of
17
CA 3002479 2018-04-23
feedstock line 106, the feed rate of feedstock line 106, and the cure rate of
feedstock
line 106.
Illustrative, non-exclusive examples of physical characteristics associated
with
feedstock line 106 that may be sensed by at least one sensor 132 include
rigidity, stiffness,
flexibility, hardness, viscosity, temperature, degree of cure, size, volume
fractions, and
shape.
In Fig. 2, communication between control system 130 and various components of
system 100 is schematically represented by lightning bolts. Such communication
may be
wired and/or wireless in nature.
Referring generally to Fig. 1 and particularly to Fig. 2, control system 130
is configured
to actively control rigidizing mechanism 112, based at least in part on at
least the one
physical characteristic, associated with feedstock line 106, to control
rigidity of resin 110 in
the rigid uncured state. The preceding subject matter of this paragraph
characterizes
example 7 of the present disclosure, wherein example 7 also includes the
subject matter
according to example 6, above.
By actively controlling rigidizing mechanism 112 based on at least one
physical
characteristic of feedstock line 106, the rigidity of feedstock line 106 in
the rigid uncured
state may be controlled to ensure that feedstock line 106 is sufficiently
rigid to be operatively
advanced by feed mechanism 126 into and through delivery guide 116.
Referring generally to Fig. 1 and particularly to Fig. 2, control system 130
is configured
to actively control feed mechanism 126, based at least in part on at least the
one physical
characteristic, associated with feedstock line 106, to control a feed rate of
feedstock line 106.
The preceding subject matter of this paragraph characterizes example 8 of the
present
disclosure, wherein example 8 also includes the subject matter according to
example 6 or 7,
above.
By actively controlling feed mechanism 126 based at least on one physical
characteristic of feedstock line 106, the feed rate of feedstock line 106 may
be controlled,
such as to ensure that rigidizing mechanism 112 has ample time to suitably
rigidize feedstock
18
CA 3002479 2018-04-23
line 106 and/or so that de-rigidizing mechanism 118 has ample time to suitably
de-rigidize
feedstock line 106.
Referring generally to Fig. 1 and particularly to Fig. 2, control system 130
is configured
to actively control de-rigidizing mechanism 118, based at least in part on at
least the one
physical characteristic, associated with feedstock line 106, to control
rigidity of resin 110 in
the second non-rigid uncured state. The preceding subject matter of this
paragraph
characterizes example 9 of the present disclosure, wherein example 9 also
includes the
subject matter according to any one of examples 6 to 8, above.
By actively controlling de-rigidizing mechanism 118 based at least on one
physical
characteristic of feedstock line 106, the second non-rigid uncured state of
feedstock line 106
may be controlled to ensure a sufficient flexibility of feedstock line 106 for
operative
deposition by delivery guide 116 along print path 114. In addition, actively
controlling de-
rigidizing mechanism 118 ensures wetting, or adhesion, between two adjacent
layers of
feedstock line 106, when a length of feedstock line 106 is being deposited
against a prior-
deposited length of feedstock line 106.
Referring generally to Fig. 1 and particularly to Fig. 2, control system 130
is configured
to actively control curing mechanism 120, based at least in part on at least
the one physical
characteristic, associated with feedstock line 106, to control a cure rate of
resin 110 of
feedstock line 106. The preceding subject matter of this paragraph
characterizes example 10
of the present disclosure, wherein example 10 also includes the subject matter
according to
any one of examples 6 to 9, above.
By actively controlling curing mechanism 120 based at least on one physical
characteristic of feedstock line 106, the intensity or power of curing energy
may be
controlled to ensure that a desired degree of cure or cure rate is imparted to
feedstock
line 106 as object 102 is being manufactured by system 100.
Referring generally to Fig. 1 and particularly to Fig. 2, system 100 further
comprises
surface 134 and drive assembly 136. Print path 114 is stationary relative to
surface 134. Drive
assembly 136 is configured to operatively and selectively move at least one of
delivery
19
CA 3002479 2018-04-23
guide 116 or surface 134 relative to each other to additively manufacture
object 102. The
preceding subject matter of this paragraph characterizes example 11 of the
present
disclosure, wherein example 11 also includes the subject matter according to
any one of
examples 1 to 10, above.
Drive assembly 136 facilitates the relative movement between delivery guide
116 and
surface 134 so that object 102 is manufactured from feedstock line 106 as it
is deposited via
delivery guide 116.
Drive assembly 136 may take any suitable form, such that delivery guide 116
and
surface 134 may be operatively moved relative to each other in three
dimensions for additive
manufacturing of object 102. In some examples, drive assembly 136 may be a
robotic arm,
and delivery guide 116 may be described as an end effector of the robotic arm.
Drive
assembly 136 may provide for relative movement between delivery guide 116 and
surface 134 in any multiple degrees of freedom, including, for example,
orthogonally in three
dimensions relative to another, in three dimensions with at least three
degrees of freedom
relative to another, in three dimensions with at least six degrees of freedom
relative to
another, in three dimensions with at least nine degrees of freedom relative to
another,
and/or in three dimensions with at least twelve degrees of freedom relative to
another.
Referring generally to Fig. 1 and particularly to Fig. 2, system 100 further
comprises
print-path heater 138, configured to heat print path 114 ahead of delivery
guide 116 as
delivery guide 116 deposits feedstock line 106 along print path 114. The
preceding subject
matter of this paragraph characterizes example 12 of the present disclosure,
wherein
example 12 also includes the subject matter according to any one of examples 1
to 11,
above.
By heating print path 114 ahead of delivery guide 116 as delivery guide 116
deposits
feedstock line 106 along print path 114, print-path heater 138 prepares the
surface against
which feedstock line 106 is deposited. For example, when feedstock line 106 is
being
deposited against a prior length of feedstock line 106 that has already been
cured, or at least
CA 3002479 2018-04-23
partially cured, by curing mechanism 120, heating of the prior length of
feedstock line 106
facilitates wetting and adhesion between the two layers of feedstock line 106.
In some examples, print-path heater 138 may utilize induction heating and/or
resistive heating, for example, with print-path heater 138 inductively and/or
electrically
coupled with elongate fibers 108 within feedstock line 106. Additionally or
alternatively,
print-path heater 138 may comprise a radiative heater and/or a laser to heat
print path 114.
Referring generally to Fig. 1 and particularly to Fig. 2, system 100 further
comprises
deposited-feedstock-line heater 140, configured to heat feedstock line 106
after feedstock
line 106 is deposited by delivery guide 116. The preceding subject matter of
this paragraph
characterizes example 13 of the present disclosure, wherein example 13 also
includes the
subject matter according to any one of examples 1 to 12, above.
By heating feedstock line 106 after it has been deposited by delivery guide
116,
deposited-feedstock-line heater 140 suitably prepares feedstock line 106,
which has already
been deposited, for subsequent deposition and adhesion of feedstock line 106
against itself.
For example, when a length of feedstock line 106 is cured, or at least
partially cured, by
curing mechanism 120, subsequent or simultaneous heating of the length of
feedstock
line 106 may facilitate adhesion between a subsequent layer of feedstock line
106 deposited
against the length of feedstock line 106. In addition, heating feedstock line
106 after it has
been deposited by delivery guide 116 may increase the degree of cure of
feedstock line 106
and may be used to control cure kinetics or cure rate of resin 110 of
feedstock line 106.
In some examples, deposited-feedstock-line heater 140 may utilize induction
heating
and/or resistive heating, for example, with deposited-feedstock-line heater
140 inductively
and/or electrically coupled with elongate fibers 108 within feedstock line
106. Additionally or
alternatively, deposited-feedstock-line heater 140 may comprise a radiative
heater and/or a
laser to heat feedstock line 106.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, method 200 of
additively
manufacturing object 102 is disclosed. Method 200 comprises (block 202)
applying resin 110
in a first non-rigid uncured state to elongate fibers 108 to create feedstock
line 106.
21
CA 3002479 2018-04-23
Feedstock line 106 comprises elongate fibers 108, at least partially
encapsulated in resin 110.
Method 200 also comprises (block 204) transforming resin 110 of feedstock line
106 from the
first non-rigid uncured state to a rigid uncured state. Feedstock line 106 and
resin 110 are
more rigid when resin 110 is in the rigid uncured state than when resin 110 is
in the first non-
rigid uncured state. Method 200 further comprises (block 206) introducing
feedstock line 106
into delivery guide 116 with resin 110 of feedstock line 106 in the rigid
uncured state.
Method 200 additionally comprises (block 208) transforming resin 110 of
feedstock line 106
from the rigid uncured state to a second non-rigid uncured state as feedstock
line 106 passes
through delivery guide 116 or as feedstock line 106 exits delivery guide 116.
Feedstock
line 106 and resin 110 are less rigid when resin 110 is in the second non-
rigid uncured state
than when resin 110 is in the rigid uncured state. Method 200 also comprises
(block 210)
depositing feedstock line 106 along print path 114, with resin 110 of
feedstock line 106 in the
second non-rigid uncured state, using delivery guide 116. Method 200 further
comprises
(block 212) at least partially curing resin 110 of feedstock line 106 after
feedstock line 106 is
deposited by delivery guide 116 along print path 114. The preceding subject
matter of this
paragraph characterizes example 14 of the present disclosure.
Method 200 therefore may be implemented to manufacture object 102 from a fiber
reinforced composite material that is created from resin 110 and elongate
fibers 108 while
object 102 is being manufactured. Moreover, method 200 may be implemented to
manufacture object 102 with elongate fibers 108 being oriented in desired
and/or
predetermined orientations throughout object 102, such as to define desired
properties of
object 102. In addition, because resin 110 is uncured when applied to elongate
fibers 108 to
create feedstock line 106, the first non-rigid uncured state of feedstock line
106 comprises
resin 110 in a viscous condition. If permitted to remain in such a viscous,
tacky, or sticky
condition, resin 110 of feedstock line 106 would be difficult to introduce
into delivery
guide 116, for example, potentially gumming up delivery guide 116 or buckling,
kinking, or
even breaking elongate fibers 108. Accordingly, transforming resin 110 to the
rigid uncured
state facilitates the introduction of feedstock line 106 into and the passage
of feedstock
22
CA 3002479 2018-04-23
line 106 through delivery guide 116, without elongate fibers 108 buckling,
breaking, or
otherwise becoming damaged, and without resin 110 soiling an associated system
(e.g.,
system 100 herein). Subsequently transforming resin 110 from the rigid uncured
state to the
second non-rigid uncured state as feedstock line 106 passes through delivery
guide 116 or as
feedstock line 106 exits delivery guide 116 results in feedstock line 106
being sufficiently
flexible to operatively be deposited in three dimensions by delivery guide 116
to additively
manufacture object 102. Depending on the properties of feedstock line 106, in
some
implementations of method 200, it may be beneficial to transform feedstock
line 106 to the
second non-rigid cured state as it passes through delivery guide 116. In other
implementations of method 200, it may be beneficial to transform feedstock
line 106 to the
second non-rigid uncured state as it exits delivery guide 116. Finally, at
least partially curing
resin 110 from the second non-rigid uncured state to an at least partially
cured state, enables
curing of object 102 as it is being manufactured, or in situ.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, feedstock line 106 in the first non-rigid uncured state has a
shear modulus less
than or equal to 0.1 GPa. Feedstock line 106 in the rigid uncured state has a
shear modulus
greater than 0.1 GPa. Feedstock line 106 in the second non-rigid uncured state
has a shear
modulus less than or equal to 0.1 GPa. The preceding subject matter of this
paragraph
characterizes example 15 of the present disclosure, wherein example 15 also
includes the
subject matter according to example 14, above.
With 0.1 GPa as a threshold shear modulus, or rigidity, feedstock line 106,
when
rigidized by rigidizing mechanism 112, is sufficiently rigid to be introduced
into delivery
guide 116 without elongate fibers 108 buckling, breaking, or otherwise
becoming damaged.
Moreover, by when having a shear modulus below 0.1 GPa, feedstock line 106 may
be
deposited along a circuitous print path, e.g., print path 114 with curves in
two or three
dimensions. However, other threshold values of shear modulus may be utilized,
such as
based on the stiffness of elongate fibers 108, the number of elongate fibers
108 in a
23
CA 3002479 2018-04-23
corresponding tow, a shape of feedstock line 106, a diameter of feedstock line
106,
properties of resin 110, etc.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, (block 204) transforming resin 110 of feedstock line 106 from the
first non-rigid
uncured state to the rigid uncured state comprises (block 214) withdrawing
heat from
resin 110 of feedstock line 106 in the first non-rigid uncured state. Also,
(block 208)
transforming resin 110 of feedstock line 106 from the rigid uncured state to
the second non-
rigid uncured state as feedstock line 106 passes through delivery guide 116 or
as feedstock
line 106 exits delivery guide 116 comprises (block 216) heating resin 110 of
feedstock
line 106 in the rigid uncured state. The preceding subject matter of this
paragraph
characterizes example 16 of the present disclosure, wherein example 16 also
includes the
subject matter according to example 14 or 15, above.
Withdrawing heat from resin 110 of feedstock line 106 to transform it to the
rigid
uncured state cools resin 110 to a sufficient degree that its shear modulus,
or rigidity, is
sufficiently high for feedstock line 106 to be introduced into delivery guide
116 without
elongate fibers 108 buckling, breaking, or otherwise becoming damaged. In some
implementations of method 200, withdrawing heat from resin 110 may be
described as
freezing resin 110. Then, to reverse the rigidity of resin 110 and feedstock
line 106, heating
resin 110 to transform it to the second non-rigid uncured state facilitates
the operative
deposition of feedstock line 106 by delivery guide 116 along print path 114.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, (block 206) introducing feedstock line 106 into delivery guide 116
with resin 110
of feedstock line 106 in the rigid uncured state comprises (block 218) pushing
feedstock
line 106 into delivery guide 116 with resin 110 of feedstock line 106 in the
rigid uncured
state. The preceding subject matter of this paragraph characterizes example 17
of the
present disclosure, wherein example 17 also includes the subject matter
according to any
one of examples 14 to 16, above.
24
CA 3002479 2018-04-23
By pushing feedstock line 106 into delivery guide 116, the feed mechanism
(e.g., feed
mechanism 126) of an associated additive manufacturing system (e.g., system
100 herein)
may be positioned upstream of delivery guide 116, and thus out of the way of
delivery
guide 116 to operatively move relative to print path 114.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, (block 218) pushing feedstock line 106 into delivery guide 116 is
performed by
opposing rollers or belts 128 that engage opposite sides of feedstock line 106
and selectively
rotate to push feedstock line 106 through delivery guide 116. The preceding
subject matter
of this paragraph characterizes example 18 of the present disclosure, wherein
example 18
also includes the subject matter according to example 17, above.
Opposing rollers or belts 128, when selectively rotated, act to frictionally
engage
feedstock line 106, thereby feeding it between opposing rollers or belts 128
and pushing it
into and through delivery guide 116.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, method 200
further
comprises (block 220) sensing at least one physical characteristic associated
with feedstock
line 106. Method 200 also comprises, responsive to (block 220) sensing at
least the one
physical characteristic associated with feedstock line 106, (block 222)
actively controlling at
least one of (block 204) transforming resin 110 of feedstock line 106 from the
first non-rigid
uncured state to the rigid uncured state, (block 206) introducing feedstock
line 106 into
delivery guide 116 with resin 110 of feedstock line 106 in the rigid uncured
state, (block 208)
transforming resin 110 of feedstock line 106 from the rigid uncured state to
the second non-
rigid uncured state as feedstock line 106 passes through delivery guide 116 or
as feedstock
line 106 exits delivery guide 116, or (block 212) at least partially curing
resin 110 of feedstock
line 106 after feedstock line 106 is deposited by delivery guide 116 along
print path 114. The
preceding subject matter of this paragraph characterizes example 19 of the
present
disclosure, wherein example 19 also includes the subject matter according to
any one of
examples 14 to 18, above.
CA 3002479 2018-04-23
By sensing at least one physical characteristic associated with feedstock line
106, an
implementation of method 200 may in real time control the rigidity of
feedstock line 106, the
feed rate of feedstock line 106, and the cure rate of feedstock line 106.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, (block 222) actively controlling (block 204) transforming resin
110 of feedstock
line 106 from the first non-rigid uncured state to the rigid uncured state
comprises
(block 224) controlling rigidity of resin 110 in the rigid uncured state. The
preceding subject
matter of this paragraph characterizes example 20 of the present disclosure,
wherein
example 20 also includes the subject matter according to example 19, above.
By actively controlling transforming resin 110 from the first non-rigid
uncured state to
the rigid uncured state, the rigidity of feedstock line 106 in the rigid
uncured state may be
controlled to ensure that feedstock line 106 is sufficiently rigid to be
operatively introduced
into and advanced through delivery guide 116.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, (block 222) actively controlling (block 206) introducing feedstock
line 106 into
delivery guide 116 with resin 110 of feedstock line 106 in the rigid uncured
state comprises
(block 226) controlling a feed rate of feedstock line 106. The preceding
subject matter of this
paragraph characterizes example 21 of the present disclosure, wherein example
21 also
includes the subject matter according to example 19 or 20, above.
By actively controlling introducing feedstock line 106 into delivery guide
116, the feed
rate of feedstock line 106 may be controlled, such as to ensure that there is
ample time to
suitably rigidize feedstock line 106 prior to its introduction into delivery
guide 116 and/or
ample time to suitably de-rigidize feedstock line 106 prior to its operative
deposition along
print path 114 by delivery guide 116.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, (block 222) actively controlling (block 208) transforming resin
110 of feedstock
line 106 from the rigid uncured state to the second non-rigid uncured state as
feedstock
line 106 passes through delivery guide 116 or as feedstock line 106 exits
delivery guide 116
26
CA 3002479 2018-04-23
comprises (block 228) controlling rigidity of resin 110 in the second non-
rigid uncured state.
The preceding subject matter of this paragraph characterizes example 22 of the
present
disclosure, wherein example 22 also includes the subject matter according to
any one of
examples 19 to 21, above.
By actively controlling transforming resin 110 from the rigid uncured state to
the
second non-rigid uncured state, the second non-rigid uncured state of
feedstock line 106
may be controlled to ensure a sufficient flexibility of feedstock line 106 for
operative
deposition by delivery guide 116 along print path 114.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, (block 222) actively controlling (block 212) at least partially
curing resin 110 of
feedstock line 106 after feedstock line 106 is deposited by delivery guide 116
along print
path 114 comprises (block 230) controlling a cure rate of resin 110 of
feedstock line 106. The
preceding subject matter of this paragraph characterizes example 23 of the
present
disclosure, wherein example 23 also includes the subject matter according to
any one of
examples 19 to 22, above.
By actively controlling at least partially curing resin 110, the cure rate
that is imparted
to feedstock line 106 as object 102 is being manufactured may be controlled.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, method 200
further
comprises (block 232) heating print path 114 ahead of delivery guide 116 as
delivery
guide 116 deposits feedstock line 106 along print path 114. The preceding
subject matter of
this paragraph characterizes example 24 of the present disclosure, wherein
example 24 also
includes the subject matter according to any one of examples 14 to 23, above.
By heating print path 114 ahead of delivery guide 116 as delivery guide 116
deposits
feedstock line 106 along print path 114, the surface against which feedstock
line 106 is
deposited is suitably prepared. For example, when feedstock line 106 is being
deposited
against a prior length of feedstock line 106 that has already been cured, or
at least partially
cured, heating of the prior length of feedstock line 106 facilitates wetting
and adhesion
between the two layers of feedstock line 106.
27
CA 3002479 2018-04-23
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, method 200
further
comprises (block 234) heating feedstock line 106 after feedstock line 106 is
deposited by
delivery guide 116 along print path 114. The preceding subject matter of this
paragraph
characterizes example 25 of the present disclosure, wherein example 25 also
includes the
subject matter according to any one of examples 14 to 24, above.
By heating feedstock line 106 after it has been deposited by delivery guide
116,
feedstock line 106, which has been deposited, is suitably prepared for
subsequent deposition
and adhesion of feedstock line 106 against itself. For example, when a length
of feedstock
line 106 is cured, or at least partially cured, subsequent or simultaneous
heating of the length
of feedstock line 106 may facilitate adhesion between a subsequent layer of
feedstock
line 106 deposited against the length of feedstock line 106.
Referring generally to Figs. 1 and 2 and particularly to Fig. 3, according to
method 200, (block 202) applying resin 110 in the first non-rigid uncured
state to elongate
fibers 108 to create feedstock line 106 comprises applying resin 110 in the
first non-rigid
uncured state to elongate fibers 108 below a threshold temperature to create
feedstock
line 106. Also, applying resin 110 in the first non-rigid uncured state to
elongate fibers 108
below the threshold temperature to create feedstock line 106 (block 204)
transforms
resin 110 of feedstock line 106 from the first non-rigid uncured state to the
rigid uncured
state. The preceding subject matter of this paragraph characterizes example 26
of the
present disclosure, wherein example 26 also includes the subject matter
according to any
one of examples 14 to 25, above.
By applying resin 110 to elongate fibers 108 that are below a threshold
temperature,
elongate fibers 108 act as a cold thermal mass, or heat sink, to withdraw heat
from resin 110
and thereby transform resin 110 to the rigid uncured state. The threshold
temperature is a
function of the properties of resin 110 and the desired rigidity of resin 110
in the rigid
uncured state.
Examples of the present disclosure may be described in the context of aircraft
manufacturing and service method 1100 as shown in Fig. 4 and aircraft 1102 as
shown in
28
CA 3002479 2018-04-23
Fig. 5. During pre-production, illustrative method 1100 may include
specification and design
(block 1104) of aircraft 1102 and material procurement (block 1106). During
production,
component and subassembly manufacturing (block 1108) and system integration
(block 1110) of aircraft 1102 may take place. Thereafter, aircraft 1102 may go
through
certification and delivery (block 1112) to be placed in service (block 1114).
While in service,
aircraft 1102 may be scheduled for routine maintenance and service (block
1116). Routine
maintenance and service may include modification, reconfiguration,
refurbishment, etc. of
one or more systems of aircraft 1102.
Each of the processes of illustrative method 1100 may be performed or carried
out by
a system integrator, a third party, and/or an operator (e.g., a customer). For
the purposes of
this description, a system integrator may include, without limitation, any
number of aircraft
manufacturers and major-system subcontractors; a third party may include,
without
limitation, any number of vendors, subcontractors, and suppliers; and an
operator may be an
airline, leasing company, military entity, service organization, and so on.
As shown in Fig. 5, aircraft 1102 produced by illustrative method 1100 may
include
airframe 1118 with a plurality of high-level systems 1120 and interior 1122.
Examples of high-
level systems 1120 include one or more of propulsion system 1124, electrical
system 1126,
hydraulic system 1128, and environmental system 1130. Any number of other
systems may
be included. Although an aerospace example is shown, the principles disclosed
herein may be
applied to other industries, such as the automotive industry. Accordingly, in
addition to
aircraft 1102, the principles disclosed herein may apply to other vehicles,
e.g., land vehicles,
marine vehicles, space vehicles, etc.
Apparatus(es) and method(s) shown or described herein may be employed during
any
one or more of the stages of the manufacturing and service method 1100. For
example,
components or subassemblies corresponding to component and subassembly
manufacturing
(block 1108) may be fabricated or manufactured in a manner similar to
components or
subassemblies produced while aircraft 1102 is in service (block 1114). Also,
one or more
examples of the apparatus(es), method(s), or combination thereof may be
utilized during
29
CA 3002479 2018-04-23
production stages 1108 and 1110, for example, by substantially expediting
assembly of or
reducing the cost of aircraft 1102. Similarly, one or more examples of the
apparatus or
method realizations, or a combination thereof, may be utilized, for example
and without
limitation, while aircraft 1102 is in service (block 1114) and/or during
maintenance and
service (block 1116).
In Fig. 6, referred to above, solid lines, if any, connecting various elements
and/or
components may represent mechanical, electrical, fluid, optical,
electromagnetic and other
couplings and/or combinations thereof. Those skilled in the art will
appreciate that some of
the features illustrated in Fig. 6 may be combined in various ways without the
need to
include other features described in Fig. 6, other drawing figures, and/or the
accompanying
disclosure, even though such combination or combinations are not explicitly
illustrated
herein. Similarly, additional features not limited to the examples presented,
may be
combined with some or all of the features shown and described herein.
In Figs. 8 and 9, referred to above, the blocks may represent operations
and/or
portions thereof and lines connecting the various blocks do not imply any
particular order or
dependency of the operations or portions thereof. Blocks represented by dashed
lines
indicate alternative operations and/or portions thereof. Dashed lines, if any,
connecting the
various blocks represent alternative dependencies of the operations or
portions thereof. It
will be understood that not all dependencies among the various disclosed
operations are
necessarily represented. Figs. 8 and 9 and the accompanying disclosure
describing the
operations of the method(s) set forth herein should not be interpreted as
necessarily
determining a sequence in which the operations are to be performed. Rather,
although one
illustrative order is indicated, it is to be understood that the sequence of
the operations may
be modified when appropriate. Accordingly, certain operations may be performed
in a
different order or simultaneously. Additionally, those skilled in the art will
appreciate that
not all operations described need be performed.
Referring generally to Fig. 6 and particularly to Fig. 7, system 2300 for
additively
manufacturing object 2102 is disclosed. System 2300 comprises source 2302 of
feedstock
CA 3002479 2018-04-23
line 2106, rigidizing mechanism 2112, delivery guide 2116, feed mechanism
2126, de-
rigidizing mechanism 2118, and curing mechanism 2120. Feedstock line 2106,
originating
from source 2302, comprises elongate fibers 2108, at least partially
encapsulated in
resin 2110 in a first at least partially uncured state. Rigidizing mechanism
2112 is to receive
feedstock line 2106 from source 2302 with resin 2110 of feedstock line 2106 in
the first at
least partially uncured state. Rigidizing mechanism 2112 is configured to
transform
resin 2110 of feedstock line 2106 from the first at least partially uncured
state to a rigid at
least partially uncured state. Feedstock line 2106 and resin 2110 are more
rigid when
resin 2110 is in the rigid at least partially uncured state than when resin
2110 is in the first at
least partially uncured state. Delivery guide 2116 is to receive feedstock
line 2106 from
rigidizing mechanism 2112 with resin 2110 in the rigid at least partially
uncured state.
Delivery guide 2116 is configured to deposit feedstock line 2106 along print
path 2114. Feed
mechanism 2126 is configured to feed feedstock line 2106 through delivery
guide 2116. De-
rigidizing mechanism 2118 is configured to transform resin 2110 of feedstock
line 2106, as
.. feedstock line 2106 passes through delivery guide 2116 or as feedstock line
2106 exits
delivery guide 2116, from the rigid at least partially uncured state to a
second at least
partially uncured state, so that, before feedstock line 2106 is deposited
along print path 2114
by delivery guide 2116, resin 2110 of feedstock line 2106, exiting delivery
guide 2116, is in
the second at least partially uncured state. Feedstock line 2106 and resin
2110 are less rigid
when resin 2110 is in the second at least partially uncured state than when
resin 2110 is in
the rigid at least partially uncured state. Curing mechanism 2120 is
configured to transform
resin 2110 of feedstock line 2106, deposited by delivery guide 2116 along
print path 2114,
from the second at least partially uncured state to an at least partially
cured state. The
preceding subject matter of this paragraph characterizes example 26 of the
present
disclosure.
System 2300 therefore may be used to manufacture object 2102 from feedstock
line 2106. Moreover, system 2300 may be used to manufacture object 2102 with
elongate
fibers 2108 being oriented in desired and/or predetermined orientations
throughout
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CA 3002479 2018-04-23
object 2102, such as to define desired properties of object 2102. Because
elongate
fibers 2108 are encapsulated in resin 2110 when feedstock line 2106 is in
source 2302,
feedstock line 2106 originating from source 2302 may be described as a prepreg
feedstock
line. In addition, because feedstock line 2106 may have a significant length,
feedstock
line 2106 in source 2302 may need to be coiled, or spooled, for source 2302 to
be compact or
otherwise manageable in size. Accordingly, feedstock line 2106 originating
from source 2302
may need to be sufficiently flexible, or bendable, to be coiled without damage
to elongate
fibers 2108, yet sufficiently rigid so that resin 2110 does not flow and so
that feedstock
line 2106 maintains its integrity as a continuous flexible line. However, the
first at least
partially uncured state of feedstock line 2106 may be too flexible to be
operably fed into and
advanced through delivery guide 2116 and may be too tacky, or sticky, to be
operably
handled by system 2300 without gumming up, or otherwise soiling, component
parts of
system 2300. Accordingly, rigidizing mechanism 2112 transforms feedstock line
2106 from
the first at least partially uncured state to the rigid at least partially
uncured state so that
feed mechanism 2126 can advance feedstock line 2106 into delivery guide 2116
without
soiling or damaging feed mechanism 2126, and without elongate fibers 2108
buckling,
breaking, or otherwise becoming damaged. Moreover, because feedstock line 2106
is then in
the rigid at least partially uncured state, it will easily be advanced through
delivery
guide 2116 for ultimate depositing along print path 2114 to manufacture object
2102.
However, feedstock line 2106 in its rigid at least partially uncured state is
too rigid for
deposition along print path 2114 in three-dimensions. Accordingly, de-
rigidizing
mechanism 2118 is provided to transform feedstock line 2106 from the rigid at
least partially
uncured state to a sufficiently non-rigid uncured state¨the second at least
partially uncured
state¨for ultimate deposition along print path 2114. Moreover, de-rigidizing
mechanism 2118 ensures appropriate wetting, or adhesion, between two adjacent
layers of
feedstock line 2106, when a length of feedstock line 2106 is being deposited
against a prior-
deposited length of feedstock line 2106. De-rigidizing mechanism 2118 may de-
rigidize
feedstock line 2106 either as it is passing through delivery guide 2116 or as
feedstock
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CA 3002479 2018-04-23
line 2106 exits delivery guide 2116, depending on the configuration of de-
rigidizing
mechanism 2118 and depending on the properties of feedstock line 2106 in the
second at
least partially uncured state. Finally, curing mechanism 2120 transforms resin
2110 from the
second at least partially uncured state to the at least partially cured state,
to at least partially
cure object 2102 while it is being manufactured, or in situ.
Some examples of system 2300 additionally or alternatively may be described as
3-D
printers.
Elongate fibers 2108 may take any suitable form and be constructed of any
suitable
material depending on desired properties of object 2102 to be manufactured by
system 2300. In one example, elongate fibers 2108 include, but are not limited
to, carbon
fibers, glass fibers, synthetic organic fibers, aramid fibers, natural fibers,
wood fibers, boron
fibers, silicon-carbide fibers, optical fibers, fiber bundles, fiber tows,
fiber weaves, fiber
braids, wires, metal wires, conductive wires, and wire bundles. Feedstock line
2106 may be
created from a single configuration, or type, of elongate fibers 2108 or may
be created from
more than one configuration, or type, of elongate fibers 2108. By "elongate,"
it is meant that
elongate fibers 2108 are generally continuous in nature along feedstock line
2106 as it is
being created, as opposed to, for example, use of chopped-fiber segments. That
said,
elongate fibers 2108 may comprise discontinuous segments of fibers that are
bundled,
woven, braided, or otherwise combined, and still be considered generally
continuous in
nature along feedstock line 2106. Elongate fibers 2108 have a length that is
significantly
longer than a dimension (e.g., diameter or width) that is transverse, or
perpendicular, to its
length. As an illustrative, non-exclusive example, elongate fibers 2108 may
have a length that
is at least 100, at least 1000, at least 10000, at least 100000, or at least
1000000 times
greater than their diameter or width.
Resin 2110 may take any suitable form depending on desired properties of
object 2102 and depending on the functionality of system 2300 and curing
mechanism 2120.
In some examples, resin 2110 may comprise a photopolymer resin that is
configured to be
cured by selective application of light. In other examples, resin 2110 may
comprise a
33
CA 3002479 2018-04-23
thermoset resin that is configured to be cured by selective application of
heat or radiation.
Other types of resin 2110 also may be used and incorporated into system 2300.
Referring generally to Fig. 6 and particularly to Fig. 7, feedstock line 2106
in the first
at least partially uncured state has a shear modulus greater than 0.08 GPa and
less than or
equal to 0.1 GPa. Feedstock line 2106 in the rigid at least partially uncured
state has a shear
modulus greater than 0.1 GPa. Feedstock line 2106 in the second at least
partially uncured
state has a shear modulus less than or equal to 0.1 GPa. The preceding subject
matter of this
paragraph characterizes example 27 of the present disclosure, wherein example
27 also
includes the subject matter according to example 26, above.
With 0.1 GPa as a threshold shear modulus, or rigidity, feedstock line 2106,
when
rigidized by rigidizing mechanism 2112, is sufficiently rigid to be advanced
by feed
mechanism 2126 into and through delivery guide 2116. Moreover, by de-
rigidizing feedstock
line 2106 below a shear modulus of 0.1 GPa, feedstock line 2106 may be
deposited along a
circuitous print path, e.g., print path 2114 with curves in two or three
dimensions. However,
other threshold values of shear modulus may be utilized, such as based on the
stiffness of
elongate fibers 2108, the number of elongate fibers 2108 in a corresponding
tow, a shape of
feedstock line 2106, a diameter of feedstock line 2106, properties of resin
2110, etc.
Referring generally to Fig. 6 and particularly to Fig. 7, rigidizing mechanism
2112 is
configured to withdraw heat from resin 2110 of feedstock line 2106 in the
first at least
partially uncured state to transform resin 2110 of feedstock line 2106 from
the first at least
partially uncured state to the rigid at least partially uncured state. De-
rigidizing
mechanism 2118 is configured to heat resin 2110 of feedstock line 2106 in the
rigid at least
partially uncured state to transform resin 2110 of feedstock line 2106 from
the rigid at least
partially uncured state to the second at least partially uncured state. The
preceding subject
matter of this paragraph characterizes example 28 of the present disclosure,
wherein
example 28 also includes the subject matter according to example 26 or 27,
above.
When rigidizing mechanism 2112 withdraws heat from resin 2110 of feedstock
line 2106 to transform it to the rigid at least partially uncured state,
rigidizing
34
CA 3002479 2018-04-23
mechanism 2112 cools resin 2110 to a sufficient degree that its shear modulus,
or rigidity, is
sufficiently high for feed mechanism 2126 to operatively advance feedstock
line 2106 into
and through delivery guide 2116 without undesirably soiling, gumming up, or
damaging feed
mechanism 2126 and delivery guide 2116. In some examples, rigidizing mechanism
2112 may
.. be described as freezing resin 2110 and/or feedstock line 2106. Then, to
reverse the rigidity
of resin 2110 and feedstock line 2106, de-rigidizing mechanism 2118 heats
resin 2110 to
transform it to the second at least partially uncured state for operative
deposition by delivery
guide 2116 along print path 2114.
Rigidizing mechanism 2112 and de-rigidizing mechanism 2118 may take any
suitable
configuration and utilize any suitable mechanism for withdrawing heat and
applying heat,
respectively. For example, rigidizing mechanism 2112 may utilize a
refrigeration cycle to
withdraw heat from resin 2110. Additionally or alternatively, rigidizing
mechanism 2112 may
utilize a cold fluid that is passed over and contacts feedstock line 2106 to
withdraw heat from
resin 2110. In some examples, de-rigidizing mechanism 2118 may be or include a
resistive
heater, an inductive heater, or a radiative heater, such as operatively
coupled to or
positioned within delivery guide 2116, such as at or adjacent to where
feedstock line 2106
exits delivery guide 2116. Additionally or alternatively, de-rigidizing
mechanism 2118 may
include or utilize a laser or a heated fluid stream to heat resin 2110. In
some examples,
curing mechanism 2120 may additionally serve as de-rigidizing mechanism 2118.
Other
.. examples of rigidizing mechanism 2112 and de-rigidizing mechanism 2118 also
are within the
scope of the present disclosure and may be incorporated into system 2300.
Referring generally to Fig. 6 and particularly to Fig. 7, feed mechanism 2126
is
configured to push feedstock line 2106 through delivery guide 2116. The
preceding subject
matter of this paragraph characterizes example 29 of the present disclosure,
wherein
example 29 also includes the subject matter according to any one of examples
26 to 28,
above.
Feed mechanism 2126 facilitates the advancement of feedstock line 2106 into,
through, and out of delivery guide 2116. By being positioned to push feedstock
line 2106
CA 3002479 2018-04-23
though delivery guide 2116, it is upstream of the exit of delivery guide 2116
and thus is
positioned out of the way of the movement of delivery guide 2116 and
deposition of
feedstock line 2106 along print path 2114.
Referring generally to Fig. 6 and particularly to Fig. 7, feed mechanism 2126
comprises opposing rollers or belts 2128, configured to engage opposite sides
of feedstock
line 2106 and to selectively rotate to push feedstock line 2106 through
delivery guide 2116.
The preceding subject matter of this paragraph characterizes example 30 of the
present
disclosure, wherein example 30 also includes the subject matter according to
example 29,
above.
Opposing rollers or belts 2128, when selectively rotated, act to frictionally
engage
feedstock line 2106, thereby feeding it between opposing rollers or belts 2128
and pushing it
into and through delivery guide 2116. Feed mechanism 2126 additionally or
alternatively
may comprise other pinch mechanisms configured to push feedstock line 2106
through
delivery guide 2116.
Referring generally to Fig. 6 and particularly to Fig. 7, system 2300 further
comprises
control system 2130 that comprises at least one sensor 2132, configured to
sense at least
one physical characteristic associated with feedstock line 2106. Control
system 2130 is
configured to actively control at least one of rigidizing mechanism 2112, feed
mechanism 2126, de-rigidizing mechanism 2118, or curing mechanism 2120, based
at least in
part on at least the one physical characteristic associated with feedstock
line 2106. The
preceding subject matter of this paragraph characterizes example 31 of the
present
disclosure, wherein example 31 also includes the subject matter according to
any one of
examples 26 to 30, above.
By sensing at least one physical characteristic associated with feedstock line
2106 and
actively controlling rigidizing mechanism 2112, feed mechanism 2126, de-
rigidizing
mechanism 2118, and/or curing mechanism 2120 based on at least one physical
characteristic associated with feedstock line 2106, system 2300 may in real
time control the
36
CA 3002479 2018-04-23
rigidity of feedstock line 2106, the feed rate of feedstock line 2106, and the
cure rate of
feedstock line 2106.
Illustrative, non-exclusive examples of physical characteristics associated
with
feedstock line 2106 that may be sensed by at least one sensor 2132 include
rigidity, stiffness,
flexibility, hardness, viscosity, temperature, degree of cure, size, volume
fractions, and
shape.
In Fig. 7, communication between control system 2130 and various components of
system 2100 is schematically represented by lightning bolts. Such
communication may be
wired and/or wireless in nature.
Referring generally to Fig. 6 and particularly to Fig. 7, control system 2130
is
configured to actively control rigidizing mechanism 2112, based at least in
part on at least
the one physical characteristic, associated with feedstock line 2106, to
control rigidity of
resin 2110 in the rigid at least partially uncured state. The preceding
subject matter of this
paragraph characterizes example 32 of the present disclosure, wherein example
32 also
includes the subject matter according to example 31, above.
By actively controlling rigidizing mechanism 2112 based on at least one
physical
characteristic of feedstock line 2106, the rigidity of feedstock line 2106 in
the rigid at least
partially uncured state may be controlled to ensure that feedstock line 2106
is sufficiently
rigid to be operatively advanced by feed mechanism 2126 into and through
delivery
guide 2116.
Referring generally to Fig. 6 and particularly to Fig. 7, control system 2130
is
configured to actively control feed mechanism 2126, based at least in part on
at least the one
physical characteristic associated with feedstock line 2106, to control a feed
rate of feedstock
line 2106. The preceding subject matter of this paragraph characterizes
example 33 of the
present disclosure, wherein example 33 also includes the subject matter
according to
example 31 or 32, above.
By actively controlling feed mechanism 2126 based at least on one physical
characteristic of feedstock line 2106, the feed rate of feedstock line 2106
may be controlled,
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CA 3002479 2018-04-23
such as to ensure that rigidizing mechanism 2112 has ample time to suitably
rigidize
feedstock line 2106 and/or so that de-rigidizing mechanism 2118 has ample time
to suitably
de-rigidize feedstock line 2106.
Referring generally to Fig. 6 and particularly to Fig. 7, control system 2130
is
configured to actively control de-rigidizing mechanism 2118, based at least in
part on at least
the one physical characteristic, associated with feedstock line 2106, to
control rigidity of
resin 2110 in the second at least partially uncured state. The preceding
subject matter of this
paragraph characterizes example 34 of the present disclosure, wherein example
34 also
includes the subject matter according to any one of examples 31 to 33, above.
By actively controlling de-rigidizing mechanism 2118 based at least on one
physical
characteristic of feedstock line 2106, the second at least partially uncured
state of feedstock
line 2106 may be controlled to ensure a sufficient flexibility of feedstock
line 2106 for
operative deposition by delivery guide 2116 along print path 2114. In
addition, actively
controlling de-rigidizing mechanism 2118 ensures wetting, or adhesion, between
two
adjacent layers of feedstock line 2106, when a length of feedstock line 2106
is being
deposited against a prior-deposited length of feedstock line 2106.
Referring generally to Fig. 6 and particularly to Fig. 7, control system 2130
is
configured to actively control curing mechanism 2120, based at least in part
on at least the
one physical characteristic, associated with feedstock line 2106, to control a
cure rate of
resin 2110 of feedstock line 2106. The preceding subject matter of this
paragraph
characterizes example 35 of the present disclosure, wherein example 35 also
includes the
subject matter according to any one of examples 31 to 34, above.
By actively controlling curing mechanism 2120 based at least on one physical
characteristic of feedstock line 2106, the intensity or power of curing energy
may be
controlled to ensure that a desired degree of cure or cure rate is imparted to
feedstock
line 2106 as object 2102 is being manufactured by system 2300.
Referring generally to Fig. 6 and particularly to Fig. 7, system 2300 further
comprises
surface 2134 and drive assembly 2136. Print path 2114 is stationary relative
to surface 2134.
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CA 3002479 2018-04-23
Drive assembly 2136 is configured to operatively and selectively move at least
one of delivery
guide 2116 or surface 2134 relative to each other to additively manufacture
object 2102. The
preceding subject matter of this paragraph characterizes example 36 of the
present
disclosure, wherein example 36 also includes the subject matter according to
any one of
examples 26 to 35, above.
Drive assembly 2136 facilitates the relative movement between delivery guide
2116
and surface 2134 so that object 2102 is manufactured from feedstock line 2106
as it is
deposited via delivery guide 2116.
Drive assembly 2136 may take any suitable form, such that delivery guide 2116
and
surface 2134 may be operatively moved relative to each other in three
dimensions for
additive manufacturing of object 2102. In some examples, drive assembly 2136
may be a
robotic arm, and delivery guide 2116 may be described as an end effector of
the robotic arm.
Drive assembly 2136 may provide for relative movement between delivery guide
2116 and
surface 2134 in any multiple degrees of freedom, including, for example,
orthogonally in
three dimensions relative to another, in three dimensions with at least three
degrees of
freedom relative to another, in three dimensions with at least six degrees of
freedom relative
to another, in three dimensions with at least nine degrees of freedom relative
to another,
and/or in three dimensions with at least twelve degrees of freedom relative to
another.
Referring generally to Fig. 6 and particularly to Fig. 7, system 2300 further
comprises
print-path heater 2138, configured to heat print path 2114 ahead of delivery
guide 2116 as
delivery guide 2116 deposits feedstock line 2106 along print path 2114. The
preceding
subject matter of this paragraph characterizes example 37 of the present
disclosure, wherein
example 37 also includes the subject matter according to any one of examples
26 to 36,
above.
By heating print path 2114 ahead of delivery guide 2116 as delivery guide 2116
deposits feedstock line 2106 along print path 2114, print-path heater 2138
prepares the
surface against which feedstock line 2106 is deposited. For example, when
feedstock
line 2106 is being deposited against a prior length of feedstock line 2106
that has already
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CA 3002479 2018-04-23
been cured, or at least partially cured, by curing mechanism 2120, heating of
the prior length
of feedstock line 2106 facilitates wetting and adhesion between the two layers
of feedstock
line 2106.
In some examples, print-path heater 2138 may utilize induction heating and/or
resistive heating, for example, with print-path heater 2138 inductively and/or
electrically
coupled with elongate fibers 2108 within feedstock line 2106. Additionally or
alternatively,
print-path heater 2138 may comprise a radiative heater and/or a laser to heat
print
path 2114.
Referring generally to Fig. 6 and particularly to Fig. 7, system 2300 further
comprises
deposited-feedstock-line heater 2140, configured to heat feedstock line 2106
after feedstock
line 2106 is deposited by delivery guide 2116. The preceding subject matter of
this paragraph
characterizes example 38 of the present disclosure, wherein example 38 also
includes the
subject matter according to any one of examples 26 to 37, above.
By heating feedstock line 2106 after it has been deposited by delivery guide
2116,
deposited-feedstock-line heater 2140 suitably prepares feedstock line 2106,
which has
already been deposited, for subsequent deposition and adhesion of feedstock
line 2106
against itself. For example, when a length of feedstock line 2106 is cured, or
at least partially
cured, by curing mechanism 2120, subsequent or simultaneous heating of the
length of
feedstock line 2106 may facilitate adhesion between a subsequent layer of
feedstock
line 2106 deposited against the length of feedstock line 2106. In addition,
heating feedstock
line 2106 after it has been deposited by delivery guide 2116 may increase the
degree of cure
of feedstock line 2106 and may be used to control cure kinetics or cure rate
of resin 2110 of
feedstock line 2106.
In some examples, deposited-feedstock-line heater 2140 may utilize induction
heating and/or resistive heating, for example, with deposited-feedstock-line
heater 2140
inductively and/or electrically coupled with elongate fibers 2108 within
feedstock line 2106.
Additionally or alternatively, deposited-feedstock-line heater 2140 may
comprise a radiative
heater and/or a laser to heat feedstock line 2106.
CA 3002479 2018-04-23
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, method 400 of
additively
manufacturing object 2102 from feedstock line 2106 is disclosed. Feedstock
line 2106
comprises elongate fibers 2108, at least partially encapsulated in resin 2110.
Method 400
comprises (block 402) transforming resin 2110 of feedstock line 2106 from a
first at least
partially uncured state to a rigid at least partially uncured state. Feedstock
line 2106 and
resin 2110 are more rigid when resin 2110 is in the rigid at least partially
uncured state than
when resin 2110 is in the first at least partially uncured state. Method 400
further comprises
(block 404) introducing feedstock line 2106 into delivery guide 2116 with
resin 2110 of
feedstock line 2106 in the rigid at least partially uncured state. Method 400
additionally
comprises (block 406) transforming resin 2110 of feedstock line 2106 from the
rigid at least
partially uncured state to a second at least partially uncured state as
feedstock line 2106
passes through delivery guide 2116 or as feedstock line 2106 exits delivery
guide 2116.
Feedstock line 2106 and resin 2110 are less rigid when resin 2110 is in the
second at least
partially uncured state than when resin 2110 is in the rigid at least
partially uncured state.
Method 400 also comprises (block 408) depositing feedstock line 2106 along
print path 2114,
with resin 2110 in the second at least partially uncured state, using delivery
guide 2116.
Method 400 further comprises (block 410) transforming resin 2110 of feedstock
line 2106
from the second at least partially uncured state to an at least partially
cured state after
feedstock line 2106 is dispensed from delivery guide 2116 along print path
2114. Resin 2110
in the at least partially cured state is cured more than resin 2110 in the
second at least
partially uncured state. The preceding subject matter of this paragraph
characterizes
example 39 of the present disclosure.
Method 400 therefore may be implemented to manufacture object 2102 from
feedstock line 2106. Moreover, method 400 may be implemented to manufacture
object 2102 with elongate fibers 2108 being oriented in desired and/or
predetermined
orientations throughout object 2102, such as to define desired properties of
object 2102.
Because elongate fibers 2108 are encapsulated in resin 2110, feedstock line
2106 may be
described as a prepreg feedstock line. In addition, because feedstock line
2106 may have a
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CA 3002479 2018-04-23
significant length, feedstock line 2106 may be coiled, or spooled, prior to
being introduced
into delivery guide 2116. Accordingly, feedstock line 2106 may need to be
sufficiently
flexible, or bendable, to be coiled without damage to elongate fibers 2108,
yet sufficiently
rigid so that resin 2110 does not flow and so that feedstock line 2106
maintains its integrity
as a continuous flexible line. However, the first at least partially uncured
state of feedstock
line 2106 may be too flexible to be operably fed into and advanced through
delivery
guide 2116 and may be too tacky, or sticky, to be operably handled by an
associated system
(e.g., system 2300 herein) without gumming up, or otherwise soiling, component
parts of the
system. Accordingly, transforming feedstock line 2106 from the first at least
partially uncured
state to the rigid at least partially uncured state facilitates the
introduction of feedstock
line 2106 into and the passage of feedstock line 2106 through delivery guide
2116, without
elongate fibers 2108 buckling, breaking, or otherwise becoming damaged, and
without
resin 2110 soiling an associated system (e.g., system 2300 herein).
Subsequently
transforming feedstock line 2106 from the rigid at least partially uncured
state to the second
at least partially uncured state as feedstock line 2106 passes through
delivery guide 2116 or
as feedstock line 2106 exits delivery guide 2116 results in feedstock line
2106 being
sufficiently flexible to be operatively deposited in three dimensions by
delivery guide 2116 to
additively manufacture object 2102. Depending on the properties of feedstock
line 2106, in
some implementations of method 400, it may be beneficial to transform
feedstock line 2106
to the second non-rigid cured state as it passes through delivery guide 2116.
In other
implementations of method 400, it may be beneficial to transform feedstock
line 2106 to the
second non-rigid uncured state as it exits delivery guide 2116. Finally, at
least partially curing
resin 2110 from the second at least partially uncured state to the at least
partially cured
state, enables curing of object 2102 as it is being manufactured, or in situ.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, according to
method 400, feedstock line 2106 in the first at least partially uncured state
has a shear
modulus greater than 0.08 GPa and less than or equal to 0.1 GPa. Feedstock
line 2106 in the
rigid at least partially uncured state has a shear modulus greater than 0.1
GPa. Feedstock
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CA 3002479 2018-04-23
line 2106 in the second at least partially uncured state has a shear modulus
less than or equal
to 0.1 GPa. The preceding subject matter of this paragraph characterizes
example 40 of the
present disclosure, wherein example 40 also includes the subject matter
according to
example 39, above.
With 0.1 GPa as a threshold shear modulus, or rigidity, feedstock line 2106,
when
rigidized by rigidizing mechanism 2112, is sufficiently rigid to be introduced
into delivery
guide 2116 without elongate fibers 2108 buckling, breaking, or otherwise
becoming
damaged. Moreover, by when having a shear modulus below 0.1 GPa, feedstock
line 2106
may be deposited along a circuitous print path, e.g., print path 2114 with
curves in two or
three dimensions. However, other threshold values of shear modulus may be
utilized, such as
based on the stiffness of elongate fibers 2108, the number of elongate fibers
2108 in a
corresponding tow, a shape of feedstock line 2106, a diameter of feedstock
line 2106,
properties of resin 2110, etc.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, according to
method 400, (block 402) transforming resin 2110 of feedstock line 2106 from
the first at least
partially uncured state to the rigid at least partially uncured state
comprises (block 412)
withdrawing heat from resin 2110 of feedstock line 2106 in the first at least
partially uncured
state. Also, (block 406) transforming resin 2110 of feedstock line 2106 from
the rigid at least
partially uncured state to the second at least partially uncured state as
feedstock line 2106
passes through delivery guide 2116 or as feedstock line 2106 exits delivery
guide 2116
comprises (block 414) heating resin 2110 of feedstock line 2106 in the rigid
at least partially
uncured state. The preceding subject matter of this paragraph characterizes
example 41 of
the present disclosure, wherein example 41 also includes the subject matter
according to
example 39 or 40, above.
Withdrawing heat from resin 2110 of feedstock line 2106 to transform it to the
rigid
at least partially uncured state cools resin 2110 to a sufficient degree that
its shear modulus,
or rigidity, is sufficiently high for feedstock line 2106 to be introduced
into delivery
guide 2116 without elongate fibers 2108 buckling, breaking, or otherwise
becoming
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CA 3002479 2018-04-23
damaged. In some implementations of method 400, withdrawing heat from resin
2110 may
be described as freezing resin 2110. Then, to reverse the rigidity of resin
2110 and feedstock
line 2106, heating resin 2110 to transform it to the second at least partially
uncured state
facilitates the operative deposition of feedstock line 2106 by delivery guide
2116 along print
path 2114.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, according to
method 400, (block 404) introducing feedstock line 2106 into delivery guide
2116 with
resin 2110 of feedstock line 2106 in the rigid at least partially uncured
state comprises
(block 416) pushing feedstock line 2106 into delivery guide 2116 with resin
2110 of feedstock
line 2106 in the rigid at least partially uncured state. The preceding subject
matter of this
paragraph characterizes example 42 of the present disclosure, wherein example
42 also
includes the subject matter according to any one of examples 39 to 41, above.
By pushing feedstock line 2106 into delivery guide 2116, the feed mechanism
(e.g.,
feed mechanism 2126) of an associated additive manufacturing system (e.g.,
system 2300
herein) may be positioned upstream of delivery guide 2116, and thus out of the
way of
delivery guide 2116 to operatively move relative to print path 2114.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, according to
method 400, (block 416) pushing feedstock line 2106 into delivery guide 2116
is performed
by opposing rollers or belts 2128 that engage opposite sides of feedstock line
2106 and
selectively rotate to push feedstock line 2106 through delivery guide 2116.
The preceding
subject matter of this paragraph characterizes example 43 of the present
disclosure, wherein
example 43 also includes the subject matter according to example 42, above.
Opposing rollers or belts 2128, when selectively rotated, act to frictionally
engage
feedstock line 2106, thereby feeding it between opposing rollers or belts 2128
and pushing it
into and through delivery guide 2116.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, method 400
further
comprises (block 418) sensing at least one physical characteristic associated
with feedstock
line 2106. Method 400 also comprises, responsive to (block 418) sensing at
least the one
44
CA 3002479 2018-04-23
physical characteristic associated with feedstock line 2106, (block 420)
actively controlling at
least one of (block 402) transforming resin 2110 of feedstock line 2106 from
the first at least
partially uncured state to the rigid at least partially uncured state, (block
404) introducing
feedstock line 2106 into delivery guide 2116 with resin 2110 of feedstock line
2106 in the
rigid at least partially uncured state, (block 406) transforming resin 2110 of
feedstock
line 2106 from the rigid at least partially uncured state to the second at
least partially
uncured state as feedstock line 2106 passes through delivery guide 2116 or as
feedstock
line 2106 exits delivery guide 2116, or (block 410) transforming resin 2110 of
feedstock
line 2106 from the second at least partially uncured state to the at least
partially cured state
after feedstock line 2106 is dispensed from delivery guide 2116 along print
path 2114. The
preceding subject matter of this paragraph characterizes example 44 of the
present
disclosure, wherein example 44 also includes the subject matter according to
any one of
examples 39 to 43, above.
By sensing at least one physical characteristic associated with feedstock line
2106, an
implementation of method 400 may in real time control the rigidity of
feedstock line 2106,
the feed rate of feedstock line 2106, and the cure rate of feedstock line
2106.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, according to
method 400, (block 420) actively controlling (block 402) transforming resin
2110 of feedstock
line 2106 from the first at least partially uncured state to the rigid at
least partially uncured
state comprises (block 422) controlling rigidity of resin 2110 in the rigid at
least partially
uncured state. The preceding subject matter of this paragraph characterizes
example 45 of
the present disclosure, wherein example 45 also includes the subject matter
according to
example 44, above.
By actively controlling transforming resin 2110 from the first at least
partially uncured
state to the rigid at least partially uncured state, the rigidity of feedstock
line 2106 in the
rigid at least partially uncured state may be controlled to ensure that
feedstock line 2106 is
sufficiently rigid to be operatively introduced into and advanced through
delivery guide 2116.
CA 3002479 2018-04-23
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, according to
method 400, (block 420) actively controlling (block 404) introducing feedstock
line 2106 into
delivery guide 2116 with resin 2110 of feedstock line 2106 in the rigid at
least partially
uncured state comprises (block 424) controlling a feed rate of feedstock line
2106. The
preceding subject matter of this paragraph characterizes example 46 of the
present
disclosure, wherein example 46 also includes the subject matter according to
example 44
or 45, above.
By actively controlling introducing feedstock line 2106 into delivery guide
2116, the
feed rate of feedstock line 2106 may be controlled, such as to ensure that
there is ample
time to suitably rigidize feedstock line 2106 prior to its introduction into
delivery guide 2116
and/or ample time to suitably de-rigidize feedstock line 2106 prior to its
operative deposition
along print path 2114 by delivery guide 2116.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, according to
method 400, (block 420) actively controlling (block 406) transforming resin
2110 of feedstock
line 2106 from the rigid at least partially uncured state to the second at
least partially
uncured state as feedstock line 2106 passes through delivery guide 2116 or as
feedstock
line 2106 exits delivery guide 2116 comprises (block 426) controlling rigidity
of resin 2110 in
the second at least partially uncured state. The preceding subject matter of
this paragraph
characterizes example 47 of the present disclosure, wherein example 47 also
includes the
subject matter according to any one of examples 44 to 46, above.
By actively controlling transforming resin 2110 from the rigid at least
partially
uncured state to the second at least partially uncured state, the second at
least partially
uncured state of feedstock line 2106 may be controlled to ensure a sufficient
flexibility of
feedstock line 2106 for operative deposition by delivery guide 2116 along
print path 2114.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, according to
method 400, (block 420) actively controlling (block 410) transforming resin
2110 of feedstock
line 2106 from the second at least partially uncured state to the at least
partially cured state
after feedstock line 2106 is dispensed from delivery guide 2116 along print
path 2114
46
CA 3002479 2018-04-23
comprises (block 428) controlling a cure rate of resin 2110 of feedstock line
2106. The
preceding subject matter of this paragraph characterizes example 48 of the
present
disclosure, wherein example 48 also includes the subject matter according to
any one of
examples 44 to 47, above.
By actively controlling at least partially curing resin 2110, the cure rate
that is
imparted to feedstock line 2106 as object 2102 is being manufactured may be
controlled.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, method 400
further
comprises (block 430) heating print path 2114 ahead of delivery guide 2116 as
delivery
guide 2116 deposits feedstock line 2106 along print path 2114. The preceding
subject matter
of this paragraph characterizes example 49 of the present disclosure, wherein
example 49
also includes the subject matter according to any one of examples 39 to 48,
above.
By heating print path 2114 ahead of delivery guide 2116 as delivery guide 2116
deposits feedstock line 2106 along print path 2114, the surface against which
feedstock
line 2106 is deposited is suitably prepared. For example, when feedstock line
2106 is being
deposited against a prior length of feedstock line 2106 that has already been
cured, or at
least partially cured, heating of the prior length of feedstock line 2106
facilitates wetting and
adhesion between the two layers of feedstock line 2106.
Referring generally to Figs. 6 and 7 and particularly to Fig. 8, method 400
further
comprises (block 432) heating feedstock line 2106 after feedstock line 2106 is
deposited by
delivery guide 2116 along print path 2114. The preceding subject matter of
this paragraph
characterizes example SO of the present disclosure, wherein example 50 also
includes the
subject matter according to any one of examples 39 to 49, above.
By heating feedstock line 2106 after it has been deposited by delivery guide
2116,
feedstock line 2106, which has been deposited, is suitably prepared for
subsequent
deposition and adhesion of feedstock line 2106 against itself. For example,
when a length of
feedstock line 2106 is cured, or at least partially cured, subsequent or
simultaneous heating
of the length of feedstock line 2106 may facilitate adhesion between a
subsequent layer of
feedstock line 2106 deposited against the length of feedstock line 2106.
47
CA 3002479 2018-04-23
Examples of the present disclosure may be described in the context of aircraft
manufacturing and service method 3100 as shown in Fig. 9 and aircraft 3102 as
shown in
Fig. 10. During pre-production, illustrative method 3100 may include
specification and design
(block 3104) of aircraft 3102 and material procurement (block 3106), During
production,
component and subassembly manufacturing (block 3108) and system integration
(block 3110) of aircraft 3102 may take place. Thereafter, aircraft 3102 may go
through
certification and delivery (block 3112) to be placed in service (block 3114).
While in service,
aircraft 3102 may be scheduled for routine maintenance and service (block
3116). Routine
maintenance and service may include modification, reconfiguration,
refurbishment, etc. of
one or more systems of aircraft 3102.
Each of the processes of illustrative method 3100 may be performed or carried
out by
a system integrator, a third party, and/or an operator (e.g., a customer). For
the purposes of
this description, a system integrator may include, without limitation, any
number of aircraft
manufacturers and major-system subcontractors; a third party may include,
without
limitation, any number of vendors, subcontractors, and suppliers; and an
operator may be an
airline, leasing company, military entity, service organization, and so on.
As shown in Fig. 10, aircraft 3102 produced by illustrative method 3100 may
include
airframe 3118 with a plurality of high-level systems 3120 and interior 3122.
Examples of high-
level systems 3120 include one or more of propulsion system 3124, electrical
system 3126,
hydraulic system 3128, and environmental system 3130. Any number of other
systems may
be included. Although an aerospace example is shown, the principles disclosed
herein may be
applied to other industries, such as the automotive industry. Accordingly, in
addition to
aircraft 3102, the principles disclosed herein may apply to other vehicles,
e.g., land vehicles,
marine vehicles, space vehicles, etc.
Apparatus(es) and method(s) shown or described herein may be employed during
any
one or more of the stages of the manufacturing and service method 3100. For
example,
components or subassemblies corresponding to component and subassembly
manufacturing
(block 3108) may be fabricated or manufactured in a manner similar to
components or
48
CA 3002479 2018-04-23
subassemblies produced while aircraft 3102 is in service (block 3114). Also,
one or more
examples of the apparatus(es), method(s), or combination thereof may be
utilized during
production stages 3108 and 3110, for example, by substantially expediting
assembly of or
reducing the cost of aircraft 3102. Similarly, one or more examples of the
apparatus or
method realizations, or a combination thereof, may be utilized, for example
and without
limitation, while aircraft 3102 is in service (block 3114) and/or during
maintenance and
service (block 3116).
Different examples of the apparatus(es) and method(s) disclosed herein include
a
variety of components, features, and functionalities. It should be understood
that the various
examples of the apparatus(es) and method(s) disclosed herein may include any
of the
components, features, and functionalities of any of the other examples of the
apparatus(es)
and method(s) disclosed herein in any combination, and all of such
possibilities are intended
to be within the scope of the present disclosure.
Many modifications of examples set forth herein will come to mind to one
skilled in
the art to which the present disclosure pertains having the benefit of the
teachings
presented in the foregoing descriptions and the associated drawings.
Therefore, it is to be understood that the present disclosure is not to be
limited to the
specific examples illustrated and that modifications and other examples are
intended to be
included within the scope of the appended claims. Moreover, although the
foregoing
description and the associated drawings describe examples of the present
disclosure in the
context of certain illustrative combinations of elements and/or functions, it
should be
appreciated that different combinations of elements and/or functions may be
provided by
alternative implementations without departing from the scope of the appended
claims.
Accordingly, parenthetical reference numerals in the appended claims are
presented for
illustrative purposes only and are not intended to limit the scope of the
claimed subject
matter to the specific examples provided in the present disclosure.
49
CA 3002479 2018-04-23
