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

Abstract: Fiber-composite parts that incorporate a very thin electrical circuit, and a method for making the parts via compression molding, are disclosed. The electrical circuit is encapsulated by a film having a melting point that exceeds the maximum temperature to which the film is exposed during compression molding. The electrical circuit is disposed in a composite ply, in a lay-up of composite plies, and electrical leads are routed through the composite plies so that the lead are accessible in the molded fiber-composite part.

Abstract: Some embodiments of a compression mold for forming a rib-and-sheet part includes a mold cavity and a mold insert. A sheet is placed in the mold cavity, and the mold insert is placed on the sheet. A preform assemblage is placed in a gap that is formed between the mold insert and the wall of the mold cavity. A mold core is biased above the preform assemblage, prior to molding operations, via a compression spring.

Abstract: Rib-and-sheet structures include a rib comprising continuous, aligned fibers. The rib is fabricated via compression molding from continuous, aligned fiber, thereby providing an aligned, continuously reinforced rib. In one embodiment, rib-and-sheet structures are produced in a two-step compression-molding process, wherein a near net-shape rib is molded, in a first mold, from fiber-bundle based preforms, and then a rib-and-sheet part is molded by placing, in a second mold, the rib with either: (i) a preformed sheet, (ii) plies that form a laminate/sheet or (iii) chopped fibers that form a sheet during the molding process. In another embodiment, rib-and-sheet structures are fabricated in a one-step compression-molding process, wherein fiber-bundle-based preforms and (i) a preformed sheet, (ii) plies that form a laminate/sheet, or (iii) chopped fibers are combined in a single mold and molded in a single step.

Abstract: A hybrid preform comprises a bundle of unidirectionally aligned fibers, and at least one partial cut that extends part of the way, but not all of the way, through a transverse cross section of the bundle of fibers at least one location along the length of the bundle.

Abstract: An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.

Abstract: Method and apparatus for splaying fibers for the forming preform charges for the production of composite discs, and for the production of composite disc, wherein rotary compaction is applied to an appropriately arranged assemblage of preforms.

Abstract: Non-standard, resin-infused fiber bundle includes localized regions of fibers having a sub-nominal amount of polymer resin positioned along its length. These regions function as “bending regions,” where the non-standard resin-infused fiber bundle can be readily deformed by virtue of the reduced amount of resin. The bending regions segregate the non-standard resin-infused fiber bundle into what is, effectively, discrete (smaller) segments of (standard) resin-infused fiber bundle. The ability to easily manipulate the non-standard, resin-infused fiber bundle via the bending regions is useful for creating fiber-bundle-based preforms, and preform charges (assemblages of fiber-bundle-based preforms).

Abstract: An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.

Abstract: A system and methods are disclosed for producing compression-molded components having one or more desired characteristics with respect to one or more objectives. In accordance with one embodiment, a parameter space comprising a set of values of a parameter is defined, where the parameter corresponds to a property of fiber bundles, and where the set of values represents all possible values of the parameter in the parameter space. The parameter space is narrowed, and a statistical model is generated based on a sampling of the narrowed parameter space. A value of the parameter is selected based on the statistical model, and a bundle of fibers conforming to the selected value is produced. A component comprising the bundle of fibers is then manufactured using a compression-molding process.

Abstract: A method for altering polymer properties for the molding of parts comprises exposing, to a scission-causing stressor, a region of a polymer form. The scission-causing stressor is controlled to achieve, in a relatively higher molecular-weight polymer at the region, an amount of scission that results in a reduction in the molecular weight of the relatively higher molecular-weight polymer, thereby forming a relatively lower molecular-weight polymer at the region.

Abstract: A compression molding method for creating fine, features having desired fiber-alignment patterns involves creating a pressure gradient in a mold cavity during the soak phase of the compression-molding process. In the illustrative embodiment, the gradient is created by movement of a structure, and results in a flow of nearby fiber and melted resin. This alters local, preexisting, non-random fiber alignments. The process imparts geometries to a part (the bulging features) that are not otherwise present on the mold surface.

Abstract: A method for making structural foam parts having continuous aligned fibers includes placing an assemblage of fiber-bundle-based preforms in an injection mold, creating a melt flow of resin and, optionally, short, loose fiber, and adding foaming agent to the melt flow. When the foaming agent/melt flow mixture is introduced into the injection mold, the foaming agent foams. The assemblage is structured and positioned so that fibers therefrom adopt a desired alignment and position in the final part. Structural foam fills the remainder of the volume of the part.

Abstract: A method for designing fiber-composite parts in which part performance and manufacturing efficiency can be traded-off against one another to provide an “optimized” design for a desired use case. In some embodiments, the method involves generating an idealized fiber map, wherein the orientation of fibers throughout the prospective part align with the anticipated load conditions throughout the part, and then modifying the idealized fiber map by various fabrication constraints to generate a process-compensated preform map.

Abstract: Some embodiments of a compression mold for forming a rib-and-sheet part includes a mold cavity and a mold insert. A sheet is placed in the mold cavity, and the mold insert is placed on the sheet. A preform assemblage is placed in a gap that is formed between the mold insert and the wall of the mold cavity. A mold core is biased above the preform assemblage, prior to molding operations, via a compression spring.

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

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

Abstract: A method useful for forming a composite part having regions in which fibers align with the principle stress vectors as well as regions having a randomized fiber alignment. To form the randomized fiber alignment, a preform cavity is formed in a preform arrangement, and the preform arrangement is molded in accordance with compression molding protocols to form a part.

Abstract: A multi-part compression mold for forming a complex part having a desired fiber alignment, and methods therefor, are disclosed. The multi-part mold comprises at least three sections. Specific arrangements of fiber-bundle-based preforms are introduced to more than one of the mold sections of the multi-part mold, and subjected to compression molding. The arrangements of preforms, in conjunction with the multi-part mold, result in a complex part having fibers that substantially align with anticipated principle stress vectors that arise in the complex part, when in use.

Abstract: A cartridge for storing and transporting fiber-bundle-based preform charges includes a plurality of cells arranged within the housing, wherein each cell is physically adapted to receive a preform charge and prevent it from moving therein as the cartridge is transported. In some embodiments, the cartridge and preform charges it conveys are serialized.