Abstract: A cutting assembly and a cutter are provided, wherein, in an apparatus for additive manufacturing with a filament, a deposition head has a body and an applicator for fixing a run of filament to a surface at a deposition location ending at a deposition termination point. The cutter assembly has a fixation element for fixing the cutter assembly relative to the deposition head, and a cutter movable relative to the fixation element. The deposition head has a deposition termination configuration and a cutting configuration, and after fixing the run of filament, the deposition head transitions from the deposition termination configuration to the cutting configuration. The cutter cuts the filament only when the deposition head is in the cutting configuration.

Abstract: A powered shearing mechanism or cutter is disclosed that comprises an asynchronous double class 1 lever and a linear actuator that uses two ganged wheels to pry the effort portion of both levers open and close the jaws. The wheels move linearly—with the distance between them kept constant—and roll along—and exert force against—parts of the levers called “bearing surfaces.” The bearing surfaces are non-planar and reflectively symmetric and their profile is customized to provide any desired ideal mechanical advantage for the cutter. In accordance with the illustrative embodiment, the profile of the bearing surfaces is a circular arc, which provides a bearing surface which is easy to precisely fabricate and that provides a fairly constant ideal mechanical advantage at each point as the cutter's blades cut through the material.

Abstract: An additive manufacturing system is disclosed that heats a feedstock and a workpiece in preparation for depositing and tamping the feedstock onto the workpiece. The system comprises a first laser/optical instrument pair for precisely heating the feedstock and a second laser/optical instrument pair for precisely heating the workpiece. The laser beam from each laser is shaped into an ellipse and each beam is rotated around an angle of rotation to ensure that the feedstock and the workpiece are properly heated. The system employs feedforward, a variety of sensors, and feedback to adjust the angle of rotation of each laser beam.

Abstract: An additive manufacturing system is disclosed that heats a feedstock and a workpiece in preparation for depositing and tamping the feedstock onto the workpiece. The system comprises a first laser/optical instrument pair for precisely heating the feedstock and a second laser/optical instrument pair for precisely heating the workpiece. The laser beam from each laser is shaped into an ellipse and each beam is rotated around an angle of rotation to ensure that the feedstock and the workpiece are properly heated. The system employs feedforward, a variety of sensors, and feedback to adjust the angle of rotation of each laser beam.

Abstract: In additive manufacturing, a method of adding a segment of fiber-reinforced thermoplastic filament. Adding a segment of filament involves three tasks: (1) determining where the segment of filament should be added, (2) depositing the segment of filament at the desired location, and (3) tamping the segment of filament to ensure adhesion and eliminate voids. Tamping the segment of filament is performed by steering a wheel along the filament. In accordance with the illustrative embodiment, the wheel is steered around a yaw axis that is offset from the wheel's axis by a distance s, where s is a positive real number.

Abstract: In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body and are used to shape the band to a desired contour. The band is connected to the one or more actuators, and is capable of being driven along its length by one or more drive wheels. For example, the band can be in the form of a loop, arranged such that the front of the loop is in contact with a front wheel, the back of the loop is in contact a rear wheel, and the bottom of the loop faces toward the surface of the object. The band assembly further comprises a compaction support supporting the band and comprising a roller that permits the band to move along its length.

Abstract: In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body and are used to shape the band to a desired contour. The band is connected to the one or more actuators, is curved toward the surface of the object to enable contact with the surface, and is capable of being driven along its length by one or more drive wheels that are under the control of a controller. The drive wheels are configured to advance the band along its length by a first distance and in response to a first signal from the controller. The controller provides the first signal based on an estimate of thermoplastic build-up on a portion of the band that overlaps the point of compaction.

Abstract: In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body at a front mounting point or a rear mounting point, or both, and are used to shape the band to a desired contour. The band is made of a flexible material, and has a first and second connecting point, wherein at least one of them is connected to the one or more actuators. The intermediate portion of the band between the connecting points is curved toward the surface of the object being manufactured to enable the portion to come into contact with and to compact the filament onto the object. The band assembly further comprises a compaction support extending from the assembly body toward an inward-facing surface of the band.

Abstract: In additive manufacturing, a method of adding a segment of fiber-reinforced thermoplastic filament. Adding a segment of filament involves three tasks: (1) determining where the segment of filament should be added, (2) depositing the segment of filament at the desired location, and (3) tamping the segment of filament to ensure adhesion and eliminate voids. Tamping the segment of filament is performed by steering a wheel along the filament. In accordance with the illustrative embodiment, the wheel is steered around a yaw axis that is offset from the wheel's axis by a distance s, where s is a positive real number.

Abstract: A filament accumulator assembly is provided containing a filament inlet for receiving a continuous filament from the filament source and a filament outlet for receiving the continuous filament from the filament inlet, the continuous filament forming a filament loop between the filament exiting the filament inlet and entering the filament outlet. The filament accumulator assembly further comprises a filament track defining at least part of an inner boundary and an outer boundary of a circuitous filament route between the filament inlet and the filament outlet, and the filament loop is bound by the filament track. The filament loop has a diameter that varies across a range of potential diameters within the filament track.

Abstract: A cutting assembly and a cutter are provided, wherein, in an apparatus for additive manufacturing with a filament, a deposition head has a body and an applicator for fixing a run of filament to a surface at a deposition location ending at a deposition termination point. The cutter assembly has a fixation element for fixing the cutter assembly relative to the deposition head, and a cutter movable relative to the fixation element. The deposition head has a deposition termination configuration and a cutting configuration, and after fixing the run of filament, the deposition head transitions from the deposition termination configuration to the cutting configuration. The cutter cuts the filament only when the deposition head is in the cutting configuration.

Abstract: A filament accumulator assembly is provided containing a filament inlet for receiving a continuous filament from the filament source and a filament outlet for receiving the continuous filament from the filament inlet, the continuous filament forming a filament loop between the filament exiting the filament inlet and entering the filament outlet. The filament accumulator assembly further comprises a filament track defining at least part of an inner boundary and an outer boundary of a circuitous filament route between the filament inlet and the filament outlet, and the filament loop is bound by the filament track. The filament loop has a diameter that varies across a range of potential diameters within the filament track.

Abstract: In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body at a front mounting point or a rear mounting point, or both, and are used to shape the band to a desired contour. The band is made of a flexible material, and has a first and second connecting point, wherein at least one of them is connected to the one or more actuators. The intermediate portion of the band between the connecting points is curved toward the surface of the object being manufactured to enable the portion to come into contact with and to compact the filament onto the object. The band assembly further comprises a compaction support extending from the assembly body toward an inward-facing surface of the band.

Abstract: In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body and are used to shape the band to a desired contour. The band is connected to the one or more actuators, is curved toward the surface of the object to enable contact with the surface, and is capable of being driven along its length by one or more drive wheels that are under the control of a controller. The drive wheels are configured to advance the band along its length by a first distance and in response to a first signal from the controller. The controller provides the first signal based on an estimate of thermoplastic build-up on a portion of the band that overlaps the point of compaction.

Abstract: In a 3D-printing system, a deposition head comprising a band assembly having a body and a band for compacting a filament onto the surface of an object being manufactured. One or more actuators are mounted on the assembly body and are used to shape the band to a desired contour. The band is connected to the one or more actuators, and is capable of being driven along its length by one or more drive wheels. For example, the band can be in the form of a loop, arranged such that the front of the loop is in contact with a front wheel, the back of the loop is in contact a rear wheel, and the bottom of the loop faces toward the surface of the object. The band assembly further comprises a compaction support supporting the band and comprising a roller that permits the band to move along its length.