A pressure foot device and system comprising a pressure foot device for forming and applying an elongate fiber tow, wherein the pressure foot device comprises a foot surface comprising a straight foot segment, a groove comprising a flared end and defining a groove midplane, and a foot shaft housing characterized by a foot shaft's axis of rotation that is orthogonal to the straight foot segment and comprised in the groove midplane.

A continuous filament additive manufacturing machine for building a part by laying down a continuous mono-filament or composite filament material layer by layer on a tool or substrate. The machine includes a system operable to move in at least three degrees of freedom, and a placement module coupled to the system and being configured to deposit the continuous filament material. The placement module includes a guide for guiding the material to the part and an ultrasonic compaction device for compacting the material as it is being deposited from the placement module. The compaction device includes an ultrasonic driver, an attachment member and a plurality of ultrasonic horns independently coupled to the attachment member and being movable independent of each other. The plurality of ultrasonic horns are ultrasonically vibrated to melt or flow the material and cause the material to fuse and be compacted to the tool or substrate.

A continuous filament additive manufacturing machine for building a part by laying down a continuous mono-filament or composite filament material layer by layer on a tool or substrate. The machine includes a system, such as a robot, operable to move in at least three degrees of freedom, and a placement module coupled to the system and being configured to deposit the continuous filament material. The placement module includes a guide for guiding the material to the part, a heat source for pre-heating the material as it is being deposited from the placement module and a compaction device for compacting the material as it is being deposited from the placement module. The compaction device includes an ultrasonic horn that is ultrasonically vibrated to melt or flow the material and cause the material to fuse and be compacted to the tool or substrate.

A composite manufacturing system is provided. The composite manufacturing system comprises a fiber placement head, a compaction roller associated with the fiber placement head, and a temperature regulation system associated with the compaction roller. The temperature regulation system is configured to actively control a temperature of the compaction roller. The temperature regulation system comprises a number of temperature sensors, a cooling system, and a controller. The number of temperature sensors are configured to detect the temperature of the compaction roller. The cooling system is associated with the compaction roller and is configured to cool the compaction roller. The controller is in communication with the number of temperature sensors and the cooling system. The controller is configured to cool the compaction roller such that the temperature is below a threshold temperature.

In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.

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.

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.

Disclosed herein is an article comprising a first group of plies having a number of plies N.sub.1 each having unidirectional tows oriented in a first direction β.sub.1 and a second group of plies having a number of plies N.sub.2 each having unidirectional tows oriented in a second direction β.sub.2; where β.sub.1 is not equal to β.sub.2; wherein N.sub.1 and N.sub.2 are both integer numbers. At least one of the first group of plies or the second group of plies has at least one tow of different thickness from another tow, has a different tow spacing from another tow spacing, or a combination thereof.

A method to design the kits and layup the reinforcement layers and core using projection system, comprising a mold having a contoured surface; a layup projection generator which: defines a plurality of mold sections; identifies the dimensions and location for a plurality of layup segments. A model-based calibration method for alignment of laser projection system is provided in which mold features are drawn digitally, incorporated into the plug(s) which form the wind turbine blade mold, and transferred into the mold. The mold also includes reflective targets which are keyed to the molded geometry wherein their position is calculated from the 3D model. This method ensures the precision level required from projection system to effectively assist with fabrication of wind turbine blades. In this method, digital location of reflectors is utilized to compensate for the mold deformations.

A method to design the kits and layup the reinforcement layers and core using projection system, comprising a mold having a contoured surface; a layup projection generator which: defines a plurality of mold sections; identifies the dimensions and location for a plurality of layup segments. A model-based calibration method for alignment of laser projection system is provided in which mold features are drawn digitally, incorporated into the plug(s) which form the wind turbine blade mold, and transferred into the mold. The mold also includes reflective targets which are keyed to the molded geometry wherein their position is calculated from the 3D model. This method ensures the precision level required from projection system to effectively assist with fabrication of wind turbine blades. In this method, digital location of reflectors is utilized to compensate for the mold deformations.