Abstract: A method for producing a bonded magnet, comprising: (i) low-shear compounding of a thermoplastic polymer and magnetic particles to form an initial homogeneous mixture thereof; (ii) feeding the initial homogeneous mixture into a plasticator comprising a low-shear single screw rotating unidirectionally toward a die orifice and housed within a heated barrel to result in heating of the initial homogeneous mixture until the thermoplastic polymer melts and forms a further homogeneous mixture, wherein said further homogeneous mixture is transported within threads of the single screw towards the die orifice and exits the die orifice as a solid pellet; (iii) conveying the solid pellet into a mold and compression molding the pellet in the mold, to form the bonded magnet, wherein the bonded magnet possesses a magnetic particle loading of at least 80 vol % and exhibits one or more magnetic properties varying by less than 5% throughout the bonded magnet.

Abstract: A hybrid additive manufacturing and thermoforming method is provided. The method includes additively manufacturing one or more reinforcing structures directly onto a polymer sheet before shaping the polymer sheet onto a mold and/or while the polymer sheet is shaped onto a mold. By leveraging the design control of additive manufacturing, reinforcing structures can be deposited onto the polymer sheet as needed based on the intended application. These reinforcing structures can comprise standard infill patterns or complex custom core designs. The present invention provides an innovative way in which to mass produce custom thermoformed components with an optimal mechanical response.

Abstract: Methods and apparatus for embedding metallic wires within polymer structures through co-extrusion printing in large-format polymer additive manufacturing (LFPAM). The method includes receiving user input for object and wire regions, performing Boolean operations on the meshes, generating printing paths, and determining an optimized order for printing. The LFPAM tool, configured with a data processing apparatus, prints the object with embedded wire and anchors supporting the wire ends. The system may include the use of a cutting tool to separate the anchors from the printed object. This disclosure improves wire alignment, support, and printing performance, enhancing the properties of wire-embedded printed structures.

Abstract: An additive manufacturing system for an additive manufacturing material and embedded short-chopped fibers includes an extruder comprising a nozzle having a nozzle flow channel. The nozzle includes a plurality of spaced apart elongated aligning structures distributed inside the nozzle flow channel and parallel to the longitudinal center axis defining alignment flow channels within the nozzle flow channel. A nozzle for additive manufacturing, a method of additive manufacturing, and a method of making a nozzle for an additive manufacturing system for and additive manufacturing material and embedded short-chopped fibers are also disclosed.

Abstract: An additive manufacturing system for additive manufacturing with an additive manufacturing material and fibers includes an extruder comprising a static-mixing nozzle having a static-mixing channel and static-mixing structures distributed inside the static-mixing channel and extending radially inward from the channel wall, and being longitudinally distributed and radially staggered over a portion of the length of the static-mixing channel. A static-mixing nozzle, a method of additive manufacturing, and a method of making a static mixing nozzle for additive manufacturing are also disclosed.

Abstract: An additive manufacturing system for additive manufacturing material with long fibers includes an extruder comprising a nozzle that includes a static-mixing portion, a compression portion, and a long fiber alignment portion. The static-mixing portion includes a static-mixing channel with static-mixing rods distributed inside and extending radially inward from a channel wall. The long fiber alignment portion has an alignment channel with a diameter DAC that is less than a diameter DSMC of the static-mixing channel. The compression portion includes with a reducing diameter from an input end to an output end of the compression channel. A nozzle and method for additive manufacturing are also disclosed.

Abstract: A vacuum insulated glazing includes first and second spaced apart glass panes having perimeter portions defining a vacuum space between the glass panes. A vacuum valve is positioned at the perimeter portions of the glass panes and includes a valve body extending between the perimeter portions of the glass panes, and having first and second ends and a fluid conduit extending from the first end to the second end of the valve body and in fluid communication with the vacuum space. A one-way valve in the fluid conduit permits fluid flow from the vacuum space, and prevents fluid flow into the vacuum space. A suction fitting is provided for connecting the valve body to a suction device. An end seal between the perimeter portions of the glass panes is provided for hermetically sealing the vacuum space. A valve for a VIG and a method of making a VIG are also disclosed.

Abstract: A method of manufacturing an article is provided. The method includes feeding a polymeric material into an extruder including a nozzle, and feeding a continuous fiber into the extruder, the continuous fiber and the polymeric material together forming a molding compound. A three-dimensional preform is formed by discharging the molding compound from the nozzle onto a deposition surface. A mold charge is formed by positioning the three-dimensional preform within a mold that includes a top mold component and a bottom mold component. The mold charge is compression molded within the mold to form a finished article.

Abstract: The current embodiments include all-polymeric protective material for mitigating lightning strike damage. The protective material includes a hybrid matrix comprising PANI and MXene dispersed within a thermosetting epoxy resin. This hybrid matrix can be painted, printed, or applied as a conductive polymeric layer to a FRCP structure, for example an aircraft fuselage, wing, empennage, control surface (aileron, flap, slats, rudder, elevator) or a wind turbine blade. The protective material not only withstands lightning strikes, but also functions as shielding against electromagnetic interference and is corrosion-resistant and lightweight.

Abstract: A simulation-assisted additive manufacturing system and method for generating an anisotropic compensation to account for non-uniform deformation due to additive manufacturing and service loading. The predicted deformation may not be fully defined. The present disclosure provides a system and method for estimating the missing deformation data through regression analysis. The present disclosure also provides an integrated framework where the various simulated-assisted design modules are configured for two-way communication and sharing access to changes to the model.

Abstract: Provided are methods and apparatus for determining a coefficient of thermal expansion (CTE) of at least a portion of a test object. An example provided method includes (i) producing information describing a reference image of the test object portion during low-temperature excitation; (ii) heating the test object portion to a higher temperature; (iii) measuring a change in temperature of the test object portion; (iv) producing information describing an image of thermal change in displacement of the test object portion at the higher temperature; (v) comparing the information describing the image of thermal change in displacement of the test object portion at the higher temperature to the information describing the reference image to produce strain information describing heating-induced changes in strain in the test object portion; and (vi) producing CTE information by correlating the strain information with the change in temperature of the test object portion.

Abstract: Disclosed is a method of generating a functional singularity at a point or collection of points. The method may include determining a relationship between one or more parameters associated with a physical structure and a spatial gradient of field values of at least one of electromagnetic energy, sound energy, particle beam, or water waves manipulated by the physical structure, configuring, according to the relationship, the spatial gradient of field values to represent a functional singularity at a point, performing backpropagation using the spatial gradient of field values to obtain design parameters corresponding to values for the one or more parameters that achieve the functional singularity at the point, and producing a physical structure having the design parameters.

Abstract: A system and method for improving additive manufacturing, including additive manufacturing toolpaths, is provided. The system and method includes a toolpath generator that obtains initial toolpaths of an object, identifies isolated paths in the toolpaths, and adds bridge connections between neighboring isolated paths in each layer to improve the toolpaths. The bridge connections facilitate the continuous and non-stop deposition of each layer according to improved toolpaths during additive manufacture, which can reduce total deposition time and improve the resultant additive manufacture.

Abstract: An improved method for obtaining high fiber volume fraction, long fiber injection molded articles is provided. According to one embodiment, the method includes forming an injection molding feedstock by cutting pre-impregnated fiber-reinforced tape into platelets. The platelets can be coated with a thin layer of polymer to allow sliding of the platelets with respect to each other at the early stages of plastication, rather than forcing relative motion of fibers with respect to each other. The method can further include the dispersion of material only in the final stages of the injection molding screw to promote gentle motion of the feedstock at the earlier stages of the plastication process. The method allows improvement of mechanical properties of articles manufactured with equipment and techniques that are prevalent in high volume automotive and consumer industries.

Abstract: A polymeric adhesive film including a conductive filler of polyaniline (PANI) and MXene is provided. The adhesive film can be painted, printed, or applied to different substrate structures, including aircraft and wind turbine blades. The adhesive film has potential as a fatigue sensor, a strain sensor, a gas sensor, a humidity sensor, and a temperature sensor, by non-limiting example. In one embodiment, a force sensing material includes a conductive filler of PANI and MXene within an organic or polymer matrix. The force sensing material is used to measure local mechanical strain by detecting the change in electrical conductivity induced by the mechanical strain. The force sensing material can also be used in other applications where local strain changes, including the detection of local humidity and local temperature.

Abstract: The current embodiments include all-polymeric protective material for mitigating lightning strike damage. The protective material includes a hybrid matrix comprising PANI and MXene dispersed within a thermosetting epoxy resin. This hybrid matrix can be painted, printed, or applied as a conductive polymeric layer to a FRCP structure, for example an aircraft fuselage, wing, empennage, control surface (aileron, flap, slats, rudder, elevator) or a wind turbine blade. The protective material not only withstands lightning strikes, but also functions as shielding against electromagnetic interference and is corrosion-resistant and lightweight.

Abstract: A method for producing a bonded magnet, comprising: (i) low-shear compounding of a thermoplastic polymer and magnetic particles to form an initial homogeneous mixture thereof; (ii) feeding the initial homogeneous mixture into a plasticator comprising a low-shear single screw rotating unidirectionally toward a die orifice and housed within a heated barrel to result in heating of the initial homogeneous mixture until the thermoplastic polymer melts and forms a further homogeneous mixture, wherein said further homogeneous mixture is transported within threads of the single screw towards the die orifice and exits the die orifice as a solid pellet; (iii) conveying the solid pellet into a mold and compression molding the pellet in the mold, to form the bonded magnet, wherein the bonded magnet possesses a magnetic particle loading of at least 80 vol % and exhibits one or more magnetic properties varying by less than 5% throughout the bonded magnet.

Abstract: A method for rapid manufacturing of three dimensional discontinuous fiber preforms is provided. The method includes the deposition of a polymeric material containing fibers on a surface to form a tailored charge for compression molding. The reinforced polymeric material may be a thermoplastic or a reactive polymer with viscosity low enough to allow flow through an orifice during deposition, yet high enough zero shear viscosity to retain the approximate shape of the deposited charge. The material can be deposited in a predetermined pattern to induce the desired mechanical properties through alignment of the fibers. This deposition can be performed in a single layer or in multiple layers. The alignment is achieved passively by shear alignment of the fibers or actively through fiber orientation control or mixing. The fibers can be of the desired material, length, and morphology, including short and long filaments.

Abstract: A simulation-assisted additive manufacturing system and method for generating an anisotropic compensation to account for non-uniform deformation due to additive manufacturing and service loading. The predicted deformation may not be fully defined. The present disclosure provides a system and method for estimating the missing deformation data through regression analysis. The present disclosure also provides an integrated framework where the various simulated-assisted design modules are configured for two-way communication and sharing access to changes to the model.

Abstract: An assembly for additive manufacturing includes a build housing including a base, a print head, and a print head support connected to the base for supporting the print head above the base. A driver system is provided for moving the print head and the base relative to one another. A build platform comprising a build support and at least one platen. The build support can be detachably engageable to the housing. The platens can be detachably engageable to the build support. The build support can include registration structure for registering the position of the build support relative to the build housing. A method of additive manufacturing is also disclosed.