Patents Assigned to Continuous Composites Inc.
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Patent number: 11760030Abstract: A method is disclosed for additively manufacturing a structure. The method may include generating at least one tool path, causing the additive manufacturing machine to place material along a first portion of the at least one tool path, and monitoring placement of the material along the first portion of the at least one tool path. The method may also include adjusting a second portion of the at least one tool path based on the placement, and causing the additive manufacturing machine to place material along the second portion of the at least one tool path after the adjusting.Type: GrantFiled: June 14, 2021Date of Patent: September 19, 2023Assignee: Continuous Composites Inc.Inventors: Logan Lalonde, Brock Adam Jahner, Mikel Negugogor, Rachael Kathleen Morris
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Patent number: 11760029Abstract: A method is disclosed for additively manufacturing a structure. The method may include generating a vector field through a 3D virtual model, and slicing the virtual model into a plurality of layers that are aligned with the vector field. The method may also include generating at least one tool path for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a material along the at least one tool path.Type: GrantFiled: June 14, 2021Date of Patent: September 19, 2023Assignee: Continuous Composites Inc.Inventors: Logan Lalonde, Brock Adam Jahner, Mikel Negugogor, Rachael Kathleen Morris
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Patent number: 11760013Abstract: A method is disclosed for additively manufacturing an object. The method may include discharging a composite material from a print head to form the object. The method may also include drawing out fewer than all components of the composite material from the print head prior to discharging.Type: GrantFiled: December 7, 2021Date of Patent: September 19, 2023Assignee: Continuous Composites Inc.Inventors: Colin Hugh Hambling, Trevor David Budge, Ryan C. Stockett
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Patent number: 11760021Abstract: A system is disclosed for use in additively manufacturing an object. The system may have a reinforcement supply, a matrix supply, and a wetting module configured to separately receive reinforcement from the reinforcement supply and matrix from the matrix supply and to discharge the reinforcement wetted with the matrix. The wetting module may include a body forming an enclosure and having an inlet end configured to receive the reinforcement and an outlet end configured to discharge the reinforcement wetted with the matrix. The wetting module may also include a plurality of nozzles dividing the enclosure into at least a wetting chamber.Type: GrantFiled: April 5, 2022Date of Patent: September 19, 2023Assignee: 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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Patent number: 11752696Abstract: A head is disclosed for an additive manufacturing system. The head may include a first outlet configured to discharge a composite material to form an object. The head may also include a second outlet located upstream of the first outlet and configured to discharge fewer than all components of the composite material.Type: GrantFiled: December 7, 2021Date of Patent: September 12, 2023Assignee: Continuous Composites Inc.Inventors: Colin Hugh Hambling, Trevor David Budge, Ryan C. Stockett
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Publication number: 20230191697Abstract: 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: ApplicationFiled: February 16, 2023Publication date: June 22, 2023Applicant: 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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Publication number: 20230150194Abstract: 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: ApplicationFiled: January 18, 2023Publication date: May 18, 2023Applicant: Continuous Composites Inc.Inventor: Kenneth Lyle TYLER
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Publication number: 20230119095Abstract: A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths to form a base layer of a joint in the structure. The method may also include depositing a second plurality of paths that pass through the joint. At least one of the second plurality of paths may extend away from the base layer through free space.Type: ApplicationFiled: October 18, 2022Publication date: April 20, 2023Applicant: 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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Publication number: 20230118530Abstract: A method is disclosed for additively manufacturing of a joint within a structure using a composite material. The method may include depositing a first path of the composite material within a first layer at the joint. The first path may have a center portion at a center of the joint, and a first portion integral with the center portion and extending away from the center portion. The first portion may form at least part of a first branch having a first density. The center of the joint may have a second density. The first density may be greater than the second density.Type: ApplicationFiled: October 18, 2022Publication date: April 20, 2023Applicant: Continuous Composites Inc.Inventors: Maxwell Joseph Johnson, Nathan Andrew Stanberg, Ryan C. Stockett, Mikel Negugopor, Chase Bosman, Logan Lalonde, Stephen Tyler Wilson, Christopher Losee
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Publication number: 20230121549Abstract: 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: ApplicationFiled: October 18, 2022Publication date: April 20, 2023Applicant: 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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Publication number: 20230122355Abstract: 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: ApplicationFiled: November 29, 2022Publication date: April 20, 2023Applicant: 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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Publication number: 20230122290Abstract: A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths within a first layer of the structure that passes through the joint in a first configuration. The method may further include applying a transformation to the first configuration to form a second configuration. The method may additionally include depositing a second plurality of paths within a second layer of the structure to at least partially overlap the first plurality of paths and pass through the joint in the second configuration.Type: ApplicationFiled: October 18, 2022Publication date: April 20, 2023Applicant: 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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Publication number: 20230114416Abstract: 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: ApplicationFiled: December 13, 2022Publication date: April 13, 2023Applicant: Continuous Composites Inc.Inventor: Kenneth Lyle TYLER
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Publication number: 20230113623Abstract: 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: ApplicationFiled: December 13, 2022Publication date: April 13, 2023Applicant: Continuous Composites Inc.Inventor: Kenneth Lyle TYLER
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Patent number: 11623394Abstract: A compactor is disclosed for use with an additive manufacturing print head. The compactor may include a housing connectable to the additive manufacturing print head. The compactor may also include a compacting wheel, and at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel. The compactor may further include a piston moveable to adjust a distance between the housing and the compacting wheel.Type: GrantFiled: May 20, 2021Date of Patent: April 11, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Kenneth Lyle Tyler, Colin Hugh Hambling
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Patent number: 11623393Abstract: A compactor is disclosed for use with an additive manufacturing print head. The compactor may include a housing connectable to the additive manufacturing print head. The compactor may also include a compacting wheel, and at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel. The compactor may further include a piston moveable to adjust a distance between the housing and the compacting wheel.Type: GrantFiled: May 20, 2021Date of Patent: April 11, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Kenneth Lyle Tyler, Colin Hugh Hambling
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Patent number: 11618208Abstract: An additive manufacturing system is disclosed for use in discharging a continuous reinforcement. The additive manufacturing system may include a support, and a compactor operatively connected to and movable by the support. The compactor may be configured to apply a pressure to the continuous reinforcement during discharge. The additive manufacturing system may also include a feed roller biased toward the compactor to sandwich the continuous reinforcement between the roller and the compactor, and a cutting mechanism at least partially recessed within at least one of the feed roller and the compactor. The cutting mechanism may be configured to selectively move radially outward to engage the continuous reinforcement.Type: GrantFiled: January 16, 2020Date of Patent: April 4, 2023Assignee: Continuous Composites Inc.Inventor: Nathan Andrew Stranberg
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Publication number: 20230100157Abstract: An actinically curable composition includes (a) at least one monomer of formula (I); (b) at least one monomer of formula (II); (c) optionally a urethane (meth)acrylate oligomer; and (d) a photoinitiator, wherein R1, R2, R3, R7, R8 and R9 are as defined. A method of making a three dimensionally printed composite article from the actinically curable composition is also provided.Type: ApplicationFiled: February 25, 2021Publication date: March 30, 2023Applicants: Arkema France, Continuous Composites, Inc.Inventors: Sean A. Nuñez, Amelia Davenport, Neil Brian Cramer
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Patent number: 11613080Abstract: 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: July 26, 2021Date of Patent: March 28, 2023Assignee: 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: 11607839Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may have a first tool center point associated with discharge of a first material, and a second tool center point associated with discharge of a second material that is a type different than the first material.Type: GrantFiled: December 20, 2021Date of Patent: March 21, 2023Assignee: Continuous Composites Inc.Inventors: Ryan C Stockett, Tyler B. Alvarado, Stephen Tyler Wilson