Abstract: Apparatuses, applicable to new or existing large envelope, 3-axes Cartesian machinery for additive manufacturing, based on Fused Deposition of thermoplastic material deposited in subsequent layers one on top of another, wherein the output nozzle dispensing the molten printing material can be oriented in space by adding 2 independent polar axes interposed between the extruder screw output and the dispensing nozzle are described. The adjustment of these polar axes may be manually set and locked in a desired position or motorized and controlled by machine CNC thus allowing a full 5-axes material deposition. Such is particularly useful in critical zones of large envelope parts where the polar orientability of the nozzle allows improved lay-up strategy results in better dimensional and structural lay-up quality.

Abstract: Apparatuses, applicable to new or existing large envelope, 3-axes Cartesian machinery for additive manufacturing, based on Fused Deposition of thermoplastic material deposited in subsequent layers one on top of another, wherein the output nozzle dispensing the molten printing material can be oriented in space by adding 2 independent polar axes interposed between the extruder screw output and the dispensing nozzle are described. The adjustment of these polar axes may be manually set and locked in a desired position or motorized and controlled by machine CNC thus allowing a full 5-axes material deposition. Such is particularly useful in critical zones of large envelope parts where the polar orientability of the nozzle allows improved lay-up strategy results in better dimensional and structural lay-up quality.

Abstract: A fiber placement system is provided. The fiber placement system provides a plurality of working zones relative to a common gantry system. Such a configuration permits for the use of one working zone while another working zone is loaded/unloaded with parts. Also provided is a method for manufacturing composite parts using a fiber placement system having a plurality of working zones arranged relative to a common gantry.

Abstract: Process and apparatus, applicable to new or existing machinery for additive manufacturing, based on Fused Deposition of thermoplastic material deposited in subsequent layers one on top of another, wherein the process can be carried out preventing abnormal conditions in which the old layer about to receive a new layer has a surface temperature below a desired limit, that is below which bond strength is compromised and the resulting part defective. This feature is particularly useful in large envelope parts where the previous layer zone, which is about to receive a new layer thereon, has reached a surface temperature below said threshold limit. The apparatus comprises a heating system featuring multiple stationary heating elements, each one of them selectively powered in order to adjust delivered energy in direction and in intensity according to layer path and extruder speed.

Abstract: A fiber placement head with secondary compaction arrangement is provided. The fiber placement head includes a frame, at least one heating module mounted to the frame, and a primary compaction roller mounted to the frame. The secondary compaction arrangement includes a secondary idle compacting roller, operating after the primary compacting roller, performing a post retracing on the tows just applied by the primary compaction roller. The secondary compaction arrangement may also include an additional (secondary) heating module interposed between the primary and secondary compaction rollers. Re-heating and re-pressing the tows addresses those tows which are insufficiently bonded to a working surface due to the tow being insufficiently tacky.

Abstract: A fiber placement system for manufacturing components from composite materials is provided. The system includes a head system mounted to a pedestal and rotatable about a center longitudinal axis of the head system. The system also includes a robot in proximity to the head system, as well as a magazine for carrying a plurality of mold assemblies. The magazine is operable to index each mold assembly to a first location where it is retrievable by the robot, and a second location where it is outside of a working envelope of the robot.

Abstract: A fiber placement system is provided. The fiber placement system provides a plurality of working zones relative to a common gantry system. Such a configuration permits for the use of one working zone while another working zone is loaded/unloaded with parts. Also provided is a method for manufacturing composite parts using a fiber placement system having a plurality of working zones arranged relative to a common gantry.

Abstract: A fiber placement system for manufacturing components from composite materials is provided. The system includes a head system mounted to a pedestal and rotatable about a center longitudinal axis of the head system. The system also includes a robot in proximity to the head system, as well as a magazine for carrying a plurality of mold assemblies. The magazine is operable to index each mold assembly to a first location where it is retrievable by the robot, and a second location where it is outside of a working envelope of the robot.

Abstract: A modular manufacturing system and methods of using are provided. The modular manufacturing system includes a plurality of manufacturing heads that perform different manufacturing processes. These heads may include multi-axial machining heads, fiber placement heads including fiber tow and fiber tape lay-up heads. The heads are fixably attachable to a single positioning system that can manipulate the various heads along a plurality of different degrees of freedom relative to a tool or material blank.

Abstract: A modular manufacturing system and methods of using are provided. The modular manufacturing system includes a plurality of manufacturing heads that perform different manufacturing processes. These heads may include multi-axial machining heads, fiber placement heads including fiber tow and fiber tape lay-up heads. The heads are fixably attachable to a single positioning system that can manipulate the various heads along a plurality of different degrees of freedom relative to a tool or material blank.

Abstract: A vertical load weighing system and method are provided. The system includes a rail and a plurality of trucks slidable on the rail. The plurality of trucks support a saddle that carries a portion of a machine. A load measuring means is situated underneath a portion of the rail and is operable to sense the loading of each truck from the saddle and its associated machinery. The load measuring means is in operable communication with a controller that collects the sensed loading from the load measuring means. The controller is operable to provide an output indicative of the loading of each truck to allow an operator to dimensionally adjust each truck to achieve a balanced loading across the plurality of trucks.

Abstract: A fiber placement system including positioner and a fiber delivery apparatus having a creel assembly and a fiber placement head is provided. The positioner moves the entire fiber delivery apparatus including the creel assembly and the fiber placement head via at least three linear degrees of freedom. The fiber delivery apparatus includes an articulating wrist for moving the fiber placement head relative to the creel assembly. The fiber placement apparatus is substantially free of linear degrees of freedom within the fiber tow paths between the spools and the fiber placement head. One or more rotational degrees of freedom may be provided along the tow path. In one embodiment, the interface between the fiber delivery apparatus and the positioner is laterally offset such that a portion of the creel axially overlaps with vertical ram of the positioner.

Abstract: A fiber placement system including positioner and a fiber delivery apparatus having a creel assembly and a fiber placement head is provided. The positioner moves the entire fiber delivery apparatus including the creel assembly and the fiber placement head via at least three linear degrees of freedom. The fiber delivery apparatus includes an articulating wrist for moving the fiber placement head relative to the creel assembly. The fiber placement apparatus is substantially free of linear degrees of freedom within the fiber tow paths between the spools and the fiber placement head. One or more rotational degrees of freedom may be provided along the tow path. In one embodiment, the interface between the fiber delivery apparatus and the positioner is laterally offset such that a portion of the creel axially overlaps with vertical ram of the positioner.

Abstract: A modular fiber placement machine head assembly and refrigerated creel assembly affixed to a cradle for an interchangeable platform system adapted for composite fiber manufacturing through an automated, computer controlled, fiber placement machine is described.

Abstract: A method and apparatus are provided, for clamping a fiber placement tool to a fiber placement machine, along a rotational axis of the fiber placement machine, through use of a clamping apparatus having a plurality of drive lugs extending axially from the machine, and having three intersecting faying surfaces thereof which mate simultaneously in substantially intimate contact with three corresponding intersecting faying surfaces of a plurality of drive lug receptacles extending axially from the tool. Pairs of movable tines, disposed on opposite sides of each drive lug, pull the drive lugs into intimate contact with the drive lug receptacles. Master fixtures are used for setting the drive lugs and lug receptacles with respect to corresponding ones of the other, to achieve a desired intimate fit between faying surfaces thereof.

Abstract: A modular manufacturing system and methods of using are provided. The modular manufacturing system includes a plurality of manufacturing heads that perform different manufacturing processes. These heads may include multi-axial machining heads, fiber placement heads including fiber tow and fiber tape lay-up heads. The heads are fixably attachable to a single positioning system that can manipulate the various heads along a plurality of different degrees of freedom relative to a tool or material blank.

Abstract: A method and apparatus are provided for substantially containing dust generated along a fiber tow path extending from a creel to a compression roller in an automated fiber placement machine, by enclosing substantially all of the path of the fiber tows between the creel and the compression roller within a barrier that is substantially impermeable to dust. A dust collection apparatus may have a porous media and/or utilize an electrostatic charge for entrapping the dust.

Abstract: A method and apparatus are provided for forming a composite structure with an automatic placement head, through the use of a non-rotating tooling tablet having first and second substantially oppositely facing surfaces thereof, joined around the peripheries thereof by a side surface of the tablet, with at least one of the first or second surfaces forming a tool surface of the tablet. Layers of pre-impregnated fiber or tape are applied to the tool surface of the tablet by the automated fiber placement head.

Abstract: An apparatus and method are provided for performing, on-the-fly, real time inspection of a composite structure formed by an automated fiber placement machine, through comparison of a visual image of at least a portion of the composite structure to a virtual image of the composite structure. Proper formation of the structure, and/or anomalies within the structure, are determined by comparing the visual image to the virtual image. The automated fiber placement machine, and/or tooling upon which the fiber is placed, are manipulated, and a visual indicator are provided to facilitate inspection and/or repair of any detected anomalies during fabrication of the composite structure.

Abstract: An apparatus and method are provided, for selectively clamping a fiber tow against a support in a fiber placement head, in a manner allowing one-way motion of the tow in a forward direction from an input side to an output side of the support, and precluding motion of the tow in a reverse direction from the output side to the input side of the support, through use of a tow catch apparatus mounted on the fiber placement head, at a position along the forward path of the tow before the shears and clamps of a cut/add mechanism.