Patents Assigned to Continuous Composites Inc.
  • Additive manufacturing system having automated reinforcement threading
    Patent number: 11014290
    Abstract: An additive manufacturing system is disclosed. The additive manufacturing system may include a moveable support, and a print head connected to the moveable support. The print head may be configured to discharge a continuous reinforcement that is wetted with a liquid matrix. The additive manufacturing system may also include an auto-threader configured to thread the continuous reinforcement through the print head, and a controller in communication with the moveable support, the print head, and the auto-threader. The controller may be configured to selectively activate the auto-threader at a start of a manufacturing process.
    Type: Grant
    Filed: January 2, 2018
    Date of Patent: May 25, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett
  • Additive manufacturing system having in-head fiber-teasing
    Patent number: 10994481
    Abstract: A head is disclosed for an additive manufacturing system having a support. The head may include a body connectable to and moveable by the support. The body may have a discharge end configured to discharge a composite material. The head may also include a wetting location inside the body at which a continuous reinforcement is wetted with a matrix to form the composite material, and a fiber-teasing mechanism located inside the body and upstream of the discharge end and the wetting location. The body and fiber-teasing mechanism may be configured to move together during movement of the support.
    Type: Grant
    Filed: December 5, 2019
    Date of Patent: May 4, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett, Kaleb Forrest Beebout
  • Additive manufacturing system for fabricating custom support structure
    Patent number: 10993289
    Abstract: An additive manufacturing system is disclosed. The additive manufacturing system may include a plate having a plurality of print heads arranged in a grid and each configured to discharge a curable material, and at least one shuttle having a plurality of print heads arranged in a row and each configured to discharge a curable material. The additive manufacturing system may also include at least one cure enhancer associated with at least one of the plate and the at least one shuttle. The at least one cure enhancer may be configured to cure the curable material as the curable material is being discharged. The additive manufacturing system may further include at least one actuator configured to move at least one of the plate and the at least one shuttle during discharge of the curable material.
    Type: Grant
    Filed: February 14, 2018
    Date of Patent: April 27, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett
  • ADDITIVE MANUFACTURING SYSTEM
    Publication number: 20210114294
    Abstract: A system is disclosed for additively manufacturing a structure. The system may include a support and a discharge head connected to and moved by the support. The discharge head may have a wetting mechanism configured to apply a matrix to a continuous reinforcement, an outlet configured to discharge the matrix-wetted continuous reinforcement, and a cure enhancer configured to expose the matrix to a cure energy at discharge. The system may also include a dispenser mounted to the discharge head and configured to selectively advance particles toward at least one of the matrix and the continuous reinforcement, and a processor programmed to regulate the dispenser and affect a parameter linked to the particles in a variable manner along at least a length of the continuous reinforcement.
    Type: Application
    Filed: August 18, 2020
    Publication date: April 22, 2021
    Applicant: Continuous Composites Inc.
    Inventor: Jeremiah R Smith
  • Head and system for continuously manufacturing composite tube
    Patent number: 10981327
    Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include coating a continuous strand with a matrix, discharging a composite tubular structure made from the coated continuous strand, and exposing the matrix in the composite tubular structure to light to cure the matrix during discharging. The method may also include depositing a material layer onto an internal surface of the composite tubular structure as the composite tubular structure is being discharged, and wiping a squeegee over the material layer.
    Type: Grant
    Filed: June 27, 2019
    Date of Patent: April 20, 2021
    Assignee: Continuous Composites inc.
    Inventors: Kenneth Lyle Tyler, Jeff Beebout
  • Additive manufacturing system having interchangeable nozzle tips
    Patent number: 10967569
    Abstract: A head is disclosed for use with an additive manufacturing system. The head may include a matrix reservoir, a first nozzle tip, and a second nozzle tip. The head may also include a tip changer mechanically connected between the first nozzle tip, the second nozzle tip, and the matrix reservoir.
    Type: Grant
    Filed: October 2, 2017
    Date of Patent: April 6, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth L. Tyler, Ryan C Stockett
  • SYSTEM FOR ADDITIVE MANUFACTURING
    Publication number: 20210094230
    Abstract: A system is disclosed for additive manufacturing of a composite structure. The system may include an outlet through which a composite material is discharged, and a nose that is a component separate from the outlet and located at a distal end of the outlet. The nose may be biased axially relative to the outlet, from a retracted position to an extended position. The nose extends axially past the distal end of the outlet in the extended position.
    Type: Application
    Filed: September 24, 2019
    Publication date: April 1, 2021
    Applicant: Continuous Composites Inc.
    Inventors: KENNETH LYLE TYLER, ANDREW JOHN OVERBY, RYAN C. STOCKETT
  • SYSTEM FOR ADDITIVELY MANUFACTURING COMPOSITE STRUCTURE
    Publication number: 20210086436
    Abstract: A system is disclosed for us in 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 include a wetting mechanism configured to at least partially wet a continuous reinforcement with a matrix at a location inside the print head, and an outlet configured to discharge the coated continuous reinforcement. The print head may also include a compactor located downstream of the outlet and configured to compact the coated continuous reinforcement, a cure enhancer configured to expose the matrix to a cure energy, and a temperature regulating element configured to regulate a temperature of the matrix at a location upstream of the cure enhancer.
    Type: Application
    Filed: July 21, 2020
    Publication date: March 25, 2021
    Applicant: Continuous Composites Inc.
    Inventors: Trevor David BUDGE, Nathan Andrew Stranberg
  • SYSTEM FOR ADDITIVELY MANUFACTURING A STRUCTURE
    Publication number: 20210086444
    Abstract: A system is disclosed for us in additively manufacturing a structure. The system may include a chamber, a support, and a print head connected to and moveable by the support. The print head may be configured to discharge a structural material into the chamber to form a structure. The system may also include a supply device configured to direct a support material into the chamber around the structure.
    Type: Application
    Filed: July 28, 2020
    Publication date: March 25, 2021
    Applicant: Continuous Composites Inc.
    Inventors: Stephen Tyler WILSON, Ryan C. Stockett
  • SYSTEM FOR ADDITIVELY MANUFACTURING A STRUCTURE
    Publication number: 20210086452
    Abstract: A system is disclosed for additively manufacturing a structure. The system may include a support, a platform, and a print head connected to and moveable by the support. The print head may be configured to discharge a material onto the platform to build up a structure in an axial direction away from the platform. The system may also include a controller programmed to determine a threshold height of the structure in the axial direction at which continued discharge of the material from the print head will cause the structure to deviate from a desired location in a radial direction that is orthogonal to the axial direction, and to coordinate operation of the print head with operation of the support to fabricate at least one support that extends away from the structure at the threshold height to resist deviation of the structure from the desired location in the radial direction.
    Type: Application
    Filed: July 30, 2020
    Publication date: March 25, 2021
    Applicant: Continuous Composites Inc
    Inventor: Rachael Kathleen MORRIS
  • Additive manufacturing system having vibrating nozzle
    Patent number: 10953598
    Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a nozzle configured to discharge a composite material, including a matrix and a continuous reinforcement. The system may also include a support configured to move the nozzle in multiple dimensions during discharge of the composite material, and a vibration mechanism configured to generate oscillations within the nozzle during discharge.
    Type: Grant
    Filed: June 8, 2017
    Date of Patent: March 23, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Trevor David Budge
  • SYSTEMS AND METHODS FOR CONTROLLING ADDITIVE MANUFACTURING
    Publication number: 20210072715
    Abstract: 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 determine a plurality of tension vectors to be generated within the structure, and to generate a plan for manufacturing the structure. The plan may include tool paths that arrange continuous fibers within the structure to generate the plurality of tension vectors. The processor may also be configured to execute the computer-executable instructions to cause the additive manufacturing machine to follow the plan and manufacture the structure.
    Type: Application
    Filed: October 2, 2020
    Publication date: March 11, 2021
    Applicant: Continuous Composites Inc.
    Inventors: Ryan C. Stockett, Kenneth L. Tyler, Blake L. Alfson, Josiah D. Coad
  • Additive manufacturing system having finish-follower
    Patent number: 10940638
    Abstract: An additive manufacturing system is disclosed. The additive manufacturing system may include a matrix reservoir, a primary nozzle fluidly connected to the matrix reservoir, and a primary cure enhancer operatively connected to at least one of the matrix reservoir and the primary nozzle. The primary cure enhancer may be configured to direct a cure energy toward a tip of the primary nozzle. The additive manufacturing system may also include an auxiliary nozzle, an arm configured to mount the auxiliary nozzle at a trailing side of the primary nozzle, and a passage extending from the matrix reservoir to the auxiliary nozzle.
    Type: Grant
    Filed: December 19, 2017
    Date of Patent: March 9, 2021
    Assignee: Continuous Composites inc.
    Inventors: Kenneth Lyle Tyler, Ryan C Stockett
  • Additive manufacturing system having dynamically variable matrix supply
    Patent number: 10933584
    Abstract: A head is disclosed for an additive manufacturing system. The head may include a reservoir configured to hold a matrix, and a nozzle configured to discharge a continuous fiber received via the reservoir. The head may also include a plurality of supplies of different matrixes in fluid communication with the reservoir.
    Type: Grant
    Filed: September 12, 2017
    Date of Patent: March 2, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth L. Tyler, Ryan C Stockett
  • Additive manufacturing system and method for discharging coated continuous composites
    Patent number: 10932325
    Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to receive a continuous reinforcement, and at least one of a matrix jet and a matrix bath configured to wet the continuous reinforcement with a liquid matrix during passage through the print head. The system may also include a coating mechanism configured to dispense at least one of metallic and ceramic particles onto the wetted continuous reinforcement during passage through the print head, and at least one cure enhancer configured to at least one of cure the liquid matrix and cause the at least one of metallic and ceramic particles to coalesce around the continuous reinforcement. The system may further include a support configured to move the print head in multiple dimensions during discharging.
    Type: Grant
    Filed: February 9, 2018
    Date of Patent: February 23, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Kenneth Lyle Tyler, Ryan C. Stockett
  • Continuous reinforcement for use in additive manufacturing
    Patent number: 10919204
    Abstract: A continuous reinforcement is disclosed for use in additive manufacturing. The continuous reinforcement may include a plurality of continuous primary fibers oriented in a general axial direction of the continuous reinforcement. The continuous reinforcement may also include a plurality of secondary fibers interspersed with the plurality of continuous primary fibers and oriented generally orthogonal to the plurality of continuous primary fibers.
    Type: Grant
    Filed: January 5, 2018
    Date of Patent: February 16, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Trevor David Budge, Kenneth Lyle Tyler, Ryan C. Stockett
  • System and method for additively manufacturing functional elements into existing components
    Patent number: 10919222
    Abstract: A nozzle is disclosed for use with an additive manufacturing system. The nozzle may include a first channel fluidly connectable to a matrix reservoir and configured to discharge a liquid matrix received from the matrix reservoir. The nozzle may also include a second channel operatively connected to the first channel configured to discharge a reinforcement into a bed of the liquid matrix discharged by the first channel.
    Type: Grant
    Filed: December 29, 2017
    Date of Patent: February 16, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Blake L. Alfson, Ryan C Stockett, Kenneth Lyle Tyler
  • Print head for additive manufacturing system
    Patent number: 10906240
    Abstract: A print head is disclosed for use with an additive manufacturing system. The print head may include a nozzle having a base end, a tip end, and a cylindrical passage extending from the base end to the tip end. The print head may also include a compactor located at least partially inside of the nozzle at the tip end.
    Type: Grant
    Filed: April 24, 2018
    Date of Patent: February 2, 2021
    Assignee: Continuous Composites Inc.
    Inventor: Ryan C. Stockett
  • Systems and methods for controlling additive manufacturing
    Patent number: 10908576
    Abstract: 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: Grant
    Filed: July 20, 2017
    Date of Patent: February 2, 2021
    Assignee: Continuous Composites inc.
    Inventors: Kenneth L. Tyler, Ryan C. Stockett, Blake L. Alfson
  • Systems and methods for controlling additive manufacturing
    Patent number: 10901386
    Abstract: 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 determine a plurality of tension vectors to be generated within the structure, and to generate a plan for manufacturing the structure. The plan may include tool paths that arrange continuous fibers within the structure to generate the plurality of tension vectors. The processor may also be configured to execute the computer-executable instructions to cause the additive manufacturing machine to follow the plan and manufacture the structure.
    Type: Grant
    Filed: July 20, 2017
    Date of Patent: January 26, 2021
    Assignee: Continuous Composites Inc.
    Inventors: Ryan C. Stockett, Kenneth L. Tyler, Blake L. Alfson, Josiah D. Coad