Patents Assigned to Continuous Composites Inc.
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Publication number: 20250147478Abstract: A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to cause the additive manufacturing machine to discharge a path of composite material, including a continuous fiber and a matrix at least partially coating the continuous fiber. The processor may also be configured to execute the computer-executable instructions to monitor an energy level within the continuous fiber during discharging, to make a determination that the continuous fiber has lost continuity based on a reduction in the energy level, and to selectively interrupt the discharging based on the determination.Type: ApplicationFiled: January 8, 2025Publication date: May 8, 2025Applicant: Continuous Composites Inc.Inventors: Ryan C Stockett, Kenneth L. Tyler, Blake L. Alfson
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Patent number: 12290985Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.Type: GrantFiled: February 16, 2023Date of Patent: May 6, 2025Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Patent number: 12290983Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.Type: GrantFiled: November 29, 2022Date of Patent: May 6, 2025Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Patent number: 12290988Abstract: Methods and associated systems and apparatus for determining a tool path for use in additively manufacturing a structure. The methods may include receiving placement data indicative of a relative placement of a plurality of nodes, each node including one or more regional tool paths and each regional tool path for additively manufacturing a region of the structure. The methods may also include receiving operation data indicative of an operation to be performed in relation to at least one of the plurality of nodes, and resolving the at least one of the plurality of nodes into a resolved tool path for use in additively manufacturing the structure based on the received placement data and operation data.Type: GrantFiled: February 23, 2022Date of Patent: May 6, 2025Assignee: Continuous Composites Inc.Inventors: Mikel Negugogor, Logan Lalonde, Rachael Kathleen Morris
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Publication number: 20250100229Abstract: Methods and associated systems and apparatus are disclosed for determining a tool path for use in additively manufacturing a structure. The methods may include receiving data that at least partially defines a plurality of intersecting elongate elements forming a layer of the structure, and determining, based on the received data, a graph structure comprising a plurality of edges each representing one of the plurality of intersecting elongate elements, and a node representing an intersection of at least two of the plurality of intersecting elongate elements. The method may also include determining a plurality of regions of the structure based on the graph structure, each region comprising one or more elongate elements, and generating a plurality of tool paths for each of the plurality of regions.Type: ApplicationFiled: December 11, 2024Publication date: March 27, 2025Applicant: Continuous Composites Inc.Inventors: Mikel NEGUGOGOR, Logan Lalonde, Rachael Kathleen Morris
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Patent number: 12257772Abstract: A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.Type: GrantFiled: November 1, 2023Date of Patent: March 25, 2025Assignee: Continuous Composites Inc.Inventor: Kenneth Lyle Tyler
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Publication number: 20250050583Abstract: A method is disclosed for additively manufacturing an object. The method may include extending a first module of a print head to push a tag end of material adjacent a second module during a feeding routine. The method may also include extending the second module to push against the tag end, and activating a third module to at least partially cure the tag end and thereby adhere the tag end as an anchor.Type: ApplicationFiled: October 30, 2024Publication date: February 13, 2025Applicant: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew John Overby, Andrew Michael Stulc, Stephen Tyler Wilson, Ryan C. Stocket, Brock Adam Jahner, Christopher Losee
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Publication number: 20250050589Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include receiving from a user a sketch of a cross-section of the composite structure and a desired height. The method may also include automatically generating a virtual model of the composite structure having a plurality of layers, each with a thickness related to the height. The method may further include receiving from the user at least one infill pattern for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a continuous fiber along segments of the at least one infill pattern.Type: ApplicationFiled: October 28, 2024Publication date: February 13, 2025Applicant: Continuous Composites Inc.Inventors: Logan Lalonde, Brock Adam Jahner, Mikel Negugogor, Rachael Kathleen Morris
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Publication number: 20250018645Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, a discharge head connected to and moveable by the support, a supply of reinforcement, and a rotary tensioner located between the supply and the discharge head. The rotary tensioner may be configured to impart tension to the reinforcement and to generate a signal indicative of the tension. The system may further include a drive associated with the supply, and a controller in communication with the rotary tensioner and the drive. The controller may be configured to selectively adjust a feed parameter of the drive based on the signal to maintain a desired level of tension.Type: ApplicationFiled: October 1, 2024Publication date: January 16, 2025Applicant: Continuous Composites Inc.Inventors: Nathan Andrew STRANBERG, Andrew John Overby, Colin Hugh Hambling
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Patent number: 12162215Abstract: A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.Type: GrantFiled: November 2, 2023Date of Patent: December 10, 2024Assignee: Continuous Composites Inc.Inventor: Kenneth Lyle Tyler
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Patent number: 12134226Abstract: A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths within a first layer. Each of the first plurality of paths may have a center portion, a first portion extending away from the center portion to at least partially form a first branch, and a second portion integral extending away from the center portion opposite the first portion to at least partially form a second branch. The method may further include depositing a second plurality of paths primarily within the first layer. Each of the second plurality of paths may have a center portion, and a first portion extending away from the center portion to at least partially form a third branch of the joint. The second plurality of paths may cross over and be bonded to the first plurality of paths to form spaced-apart bumps that extend into a second layer.Type: GrantFiled: October 18, 2022Date of Patent: November 5, 2024Assignee: CONTINUOUS COMPOSITES INC.Inventors: Maxwell Joseph Johnson, Nathan Andrew Stranberg, Ryan C. Stockett, Mikel Negugogor, Chase Bosman, Logan Lalonde, Stephen Tyler Wilson, Christopher Losee
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Patent number: 12128615Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, a discharge head connected to and moveable by the support, a supply of reinforcement, and a rotary tensioner located between the supply and the discharge head. The rotary tensioner may be configured to impart tension to the reinforcement and to generate a signal indicative of the tension. The system may further include a drive associated with the supply, and a controller in communication with the rotary tensioner and the drive. The controller may be configured to selectively adjust a feed parameter of the drive based on the signal to maintain a desired level of tension.Type: GrantFiled: February 24, 2022Date of Patent: October 29, 2024Assignee: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew John Overby, Colin Hugh Hambling
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Patent number: 12128630Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include receiving from a user a sketch of a cross-section of the composite structure and a desired height. The method may also include automatically generating a virtual model of the composite structure having a plurality of layers, each with a thickness related to the height. The method may further include receiving from the user at least one infill pattern for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a continuous fiber along segments of the at least one infill pattern.Type: GrantFiled: June 14, 2021Date of Patent: October 29, 2024Assignee: Continuous Composites Inc.Inventors: Logan Lalonde, Brock Adam Jahner, Mikel Negugogor, Rachael Kathleen Morris
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Patent number: 12128613Abstract: A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.Type: GrantFiled: December 13, 2022Date of Patent: October 29, 2024Assignee: Continuous Composites Inc.Inventor: Kenneth Lyle Tyler
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Patent number: 12128607Abstract: A method is disclosed for manufacturing a joint. The method may include depositing a first path of composite material within a first layer at the joint. The first path may have a center at a center of the joint, a first portion integral with the center portion and extending away from the center portion, and a second portion integral with the center and extending away from the center portion. The method may further include depositing a second path of composite material within the first layer at the joint. The second path may have a center at the center of the joint, and a first portion integral with the center of the second path and extending away from the center of the second path. The center portion of the second path may be parallel with, abut and be bonded to the center portion of the first path.Type: GrantFiled: October 18, 2022Date of Patent: October 29, 2024Assignee: Continuous Composites Inc.Inventors: Maxwell Joseph Johnson, Nathan Andrew Stranberg, Ryan C. Stockett, Mikel Negugogor, Chase Bosman, Logan Lalonde, Stephen Tyler Wilson, Christopher Losee
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Patent number: 12030252Abstract: A print head is disclosed for use in additively manufacturing an object. The print head may have a housing, and a wetting module configured to wet a reinforcement with a liquid matrix. The print head may also include a matrix supply configured to hold a quantity of the liquid matrix and supply the liquid matrix to the wetting module.Type: GrantFiled: April 5, 2022Date of Patent: July 9, 2024Assignee: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew John Overby, Andrew Michael Stulc, Stephen Tyler Wilson, Ryan C. Stocket, Brock Adam Jahner
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Publication number: 20240217181Abstract: A method is disclosed for additively manufacturing a layer of a structure. The method may include determining a surface representing the layer of the structure, and determining a seed tool path lying on the surface. The method may further include, at each of a plurality of seed points along a length of the seed tool path, determining an offset direction that is transverse to an axis of the seed tool path at each of the plurality of seed points and parallel with the surface. The method may additionally include generating a plurality of offset points, each of which is offset in the offset direction from a corresponding one of the plurality of seed points. The method may also include determining an offset tool path based on the plurality of offset points, and causing a machine to discharge material along the offset tool path.Type: ApplicationFiled: December 22, 2023Publication date: July 4, 2024Applicant: Continuous Composites Inc.Inventors: Jeffrey J. Wyrick, Chase Bosman, Logan Lalonde
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Publication number: 20240157636Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first module configured to discharge a material, a second module configured to compact the material, and an actuator connected to the second module and configured to apply a force to the second module. The system may further include a controller in communication with the actuator. The controller may be configured to determine an operating parameter of the print head, and to selectively adjust the force applied by the actuator to the second module based on the operating parameter.Type: ApplicationFiled: November 10, 2023Publication date: May 16, 2024Applicant: Continuous Composites Inc.Inventors: Nathan Andrew STRANBERG, Andrew John Overby, Stephen Tyler Wilson, Christopher Lee Jones, Michael John Milbourne
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Patent number: 11964426Abstract: A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.Type: GrantFiled: January 18, 2023Date of Patent: April 23, 2024Assignee: Continuous Composites Inc.Inventor: Kenneth Lyle Tyler
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Patent number: 11958238Abstract: A system is disclosed for use in additively manufacturing a structure. The system may include a print head to discharge a material, and a support to move the print head during discharging to fabricate a structure. The system may also include a receiver mounted to the print head to generate a signal indicative of at least one of a shape, a size, and a location of the discharged material, and a processor in communication with the receiver and the support. The processor may be configured to generate a data cloud of the structure fabricated by the additive manufacturing system based on the signal and based on a known position of the receiver at a time of signal generation. The processor may also be configured to make a comparison of the data cloud and a virtual model of the structure during discharging, and to selectively affect discharging based on the comparison.Type: GrantFiled: July 20, 2022Date of Patent: April 16, 2024Assignee: Continuous Composites Inc.Inventors: Rachael Kathleen Morris, Ryan C. Stockett