Abstract: A fluid applicator for use in a fluid application system includes a base plate comprising at least one rail and a housing slidably coupled to the base plate. The fluid applicator also includes a plurality of fluid permeable pads positioned within the housing and a fluid delivery conduit coupled to the base plate and to the housing. The fluid applicator further includes an actuator configured to selectively move the housing and the plurality of pads along the rails between a first position and a second position. The plurality of fluid permeable pads are in flow communication with the fluid delivery conduit in the first position, and the plurality of fluid permeable pads are prevented from being in flow communication with the fluid delivery conduit in the second position.

Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.

Abstract: A fluid applicator for use in a fluid application system includes a base plate comprising at least one rail and a housing slidably coupled to the base plate. The fluid applicator also includes a plurality of fluid permeable pads positioned within the housing and a fluid delivery conduit coupled to the base plate and to the housing. The fluid applicator further includes an actuator configured to selectively move the housing and the plurality of pads along the rails between a first position and a second position. The plurality of fluid permeable pads are in flow communication with the fluid delivery conduit in the first position, and the plurality of fluid permeable pads are prevented from being in flow communication with the fluid delivery conduit in the second position.

Abstract: A fluid application system includes a pair of identical, spaced apart, fluid applicators that each include a fluid permeable pad saturated with fluid. In one implementation, each applicator includes a pair of conduits coupled to a base plate, wherein each conduit includes a slot configured to receive an end of the pad. In another embodiment, each applicator defines a reservoir between adjacent plates and channels fluid from the reservoir though openings in the plate to the pad. In another implementation, each of the applicators includes a base plate, a conduit coupled to the base plate, and a housing slidably coupled to the base plate. The housing includes a plurality of pads and is moveable to selectively prevent fluid flow between the conduit and the pads in a first position or to couple the pads in fluid communication with the conduit in the second position.

Abstract: Methods and apparatus for semi-automated tack welding of plies of a thermoplastic composite layup are described. An example welding tool includes a stabilization foot, a housing, a compaction foot, and a welder. The stabilization foot has a stabilization surface. The housing has a central axis. The housing is movable relative to the stabilization surface along the central axis of the housing. The compaction foot has a central axis and a compaction surface. The compaction surface is movable relative to the stabilization surface and to the housing along the central axis of the compaction surface. The welder has a central axis and a welding surface. The welding surface is movable relative to the stabilization surface, to the housing, and to the compaction surface along the central axis of the welder.

Abstract: Methods and apparatus for semi-automated tack welding of plies of a thermoplastic composite layup are described. An example welding tool includes a stabilization foot, a housing, a compaction foot, and a welder. The stabilization foot has a stabilization surface. The housing has a central axis. The housing is movable relative to the stabilization surface along the central axis of the housing. The compaction foot has a central axis and a compaction surface. The compaction surface is movable relative to the stabilization surface and to the housing along the central axis of the compaction surface. The welder has a central axis and a welding surface. The welding surface is movable relative to the stabilization surface, to the housing, and to the compaction surface along the central axis of the welder.

Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.

Abstract: In one aspect, A method of forming a product using an additive-manufacturing head includes forming a new layer of material of the product with the additive-manufacturing head. Forming the new layer of material includes depositing the new layer of material on an existing layer of material and melting the new layer of material so that the new layer of material is welded to the existing layer of material. The method also includes processing at least one of the new layer of material or the existing layer of material with a laser-emitting device, coupled to the additive-manufacturing head. Processing the at least one of the new layer of material or the existing layer of material with the laser-emitting device comprises smoothing a lateral surface of at least one of the new layer of material or the existing layer of material with a laser beam, emitted from the laser-emitting device.

Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.

Abstract: Multifunction end effector apparatus and methods for assembling thermoplastic composite articles are disclosed. An example apparatus for assembling a thermoplastic composite article includes a robot and an end effector coupled to the robot. The end effector includes a cutting head, a vacuum head, and a welding head.

Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.

Abstract: A fluid application system includes a pair of identical, spaced apart, fluid applicators that each include a fluid permeable pad saturated with fluid. In one implementation, each applicator includes a pair of conduits coupled to a base plate, wherein each conduit includes a slot configured to receive an end of the pad. In another embodiment, each applicator defines a reservoir between adjacent plates and channels fluid from the reservoir though openings in the plate to the pad. In another implementation, each of the applicators includes a base plate, a conduit coupled to the base plate, and a housing slidably coupled to the base plate. The housing includes a plurality of pads and is moveable to selectively prevent fluid flow between the conduit and the pads in a first position or to couple the pads in fluid communication with the conduit in the second position.

Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.

Abstract: Multifunction end effector apparatus and methods for assembling thermoplastic composite articles are disclosed. An example apparatus for assembling a thermoplastic composite article includes a robot and an end effector coupled to the robot. The end effector includes a cutting head, a vacuum head, and a welding head.

Abstract: Additive-manufacturing systems, surface-processing apparatuses, and methods of forming products using an additive-manufacturing head are provided. In one aspect, an additive-manufacturing system includes an additive-manufacturing head and a surface-processing device coupled to the additive-manufacturing head. In another aspect, a surface-processing apparatus for an additive-manufacturing head includes a housing configured to be coupled to the additive-manufacturing head and a surface-processing device coupled to the housing. In a further aspect, a method of forming a product using an additive-manufacturing head includes forming one or more layers of the product with the additive-manufacturing head and processing at least one of the one or more layers of the product with a surface-processing device coupled to the additive-manufacturing head.

Abstract: Additive-manufacturing systems, surface-processing apparatuses, and methods of forming products using an additive-manufacturing head are provided. In one aspect, an additive-manufacturing system includes an additive-manufacturing head and a surface-processing device coupled to the additive-manufacturing head. In another aspect, a surface-processing apparatus for an additive-manufacturing head includes a housing configured to be coupled to the additive-manufacturing head and a surface-processing device coupled to the housing. In a further aspect, a method of forming a product using an additive-manufacturing head includes forming one or more layers of the product with the additive-manufacturing head and processing at least one of the one or more layers of the product with a surface-processing device coupled to the additive-manufacturing head.

Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.

Abstract: Additive-manufacturing systems, surface-processing apparatuses, and methods of forming products using an additive-manufacturing head are provided. In one aspect, an additive-manufacturing system includes an additive-manufacturing head and a surface-processing device coupled to the additive-manufacturing head. In another aspect, a surface-processing apparatus for an additive-manufacturing head includes a housing configured to be coupled to the additive-manufacturing head and a surface-processing device coupled to the housing. In a further aspect, a method of forming a product using an additive-manufacturing head includes forming one or more layers of the product with the additive-manufacturing head and processing at least one of the one or more layers of the product with a surface-processing device coupled to the additive-manufacturing head.

Abstract: Fastener clearing systems and methods for a fastener delivery system are provided. In one embodiment, a system includes an extractor tool having one or more vacuum generators in fluid communication with a catcher for retaining fasteners during transport. The vacuum generators are selectively activated to draw fasteners into the catcher. A backflow port is formed in the extractor tool and introduces pressurized air into the catcher to dislodge fasteners that adhere to the catcher after the vacuum generators have been deactivated. The backflow port may be formed in a fitting positioned between vacuum generators and securing the vacuum generators to one another. The vacuum generators and fitting may define a common fluid channel opening into a fastener seat adapted to receive a portion of a fastener.

Abstract: Fastener clearing systems and methods for a fastener delivery system are provided. In one embodiment, a system includes an extractor tool having one or more vacuum generators in fluid communication with a catcher for retaining fasteners during transport. The vacuum generators are selectively activated to draw fasteners into the catcher. A backflow port is formed in the extractor tool and introduces pressurized air into the catcher to dislodge fasteners that adhere to the catcher after the vacuum generators have been deactivated. The backflow port may be formed in a fitting positioned between vacuum generators and securing the vacuum generators to one another. The vacuum generators and fitting may define a common fluid channel opening into a fastener seat adapted to receive a portion of a fastener.