公开(公告)号：US20220184880A1

公开(公告)日：2022-06-16

申请号：US17122343

申请日：2020-12-15

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Talbot P. Thrasher ,  Timothy E. Dominick

IPC: B29C64/118 ,  B29C64/188 ,  B33Y40/20

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

公开(公告)号：US11173654B2

公开(公告)日：2021-11-16

申请号：US16380208

申请日：2019-04-10

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Pedro A. Gonzalez ,  Todd L. Szallay ,  Steven J. Floyd ,  Sung S. Park ,  Brett G. Morham ,  Cody J. Brown ,  Reese R. Allen ,  Ryan L. Bischoff

IPC: B29C64/118 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y70/00 ,  B29C64/20

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing an alternating sequence of first part layers including rows of filaments made of a first part material and depositing second part layers including rows of filaments made of a second part material, where the second part material is different than the first part material and provides adhesion between the first part layers.

公开(公告)号：US20200324473A1

公开(公告)日：2020-10-15

申请号：US16380390

申请日：2019-04-10

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Pedro A. Gonzalez ,  Todd L. Szallay ,  Steven J. Floyd ,  Sung S. Park ,  Brett G. Morham ,  Cody J. Brown ,  Reese R. Allen ,  Ryan L. Bischoff

IPC: B29C64/209 ,  B29C64/118

Abstract: A printing machine for fabricating high performance 3D integrated composite structures, where the machine includes a robot having a base portion, a robot arm and an end joint secured to the arm opposite to the base portion, a plurality of sources of extrudable material, and an end-effector mounted to the end joint. The end-effector includes a multiple-extruder module having a first extruder and a second extruder each including a separate nozzle assembly, wherein the first extruder receives one extrudable material and the second extruder receives another extrudable material.

公开(公告)号：US20200324460A1

公开(公告)日：2020-10-15

申请号：US16380208

申请日：2019-04-10

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Pedro A. Gonzalez ,  Todd L. Szallay ,  Steven J. Floyd ,  Sung S. Park ,  Brett G. Morham ,  Cody J. Brown ,  Reese R. Allen ,  Ryan L. Bischoff

IPC: B29C64/118 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y70/00 ,  B29C64/20

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing an alternating sequence of first part layers including rows of filaments made of a first part material and depositing second part layers including rows of filaments made of a second part material, where the second part material is different than the first part material and provides adhesion between the first part layers.

公开(公告)号：US20200324458A1

公开(公告)日：2020-10-15

申请号：US16380066

申请日：2019-04-10

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Pedro A. Gonzalez ,  Todd L. Szallay ,  Steven J. Floyd ,  Sung S. Park ,  Brett G. Morham ,  Cody J. Brown ,  Reese R. Allen ,  Ryan L. Bischoff

IPC: B29C64/118 ,  B29C64/209 ,  B29C64/245 ,  B29C64/379

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing consecutive part layers each including rows of filaments made of a part material from the machine, where depositing each part layer includes non-sequentially depositing one set of a plurality of filaments so that a gap is formed between the filaments and then depositing any number of additional sets of filaments so that each adjacent pair of filaments in each additional set of filaments are non-sequentially deposited.

公开(公告)号：US11701816B2

公开(公告)日：2023-07-18

申请号：US17122343

申请日：2020-12-15

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Talbot P. Thrasher ,  Timothy E. Dominick

IPC: B29C64/118 ,  B29C64/188 ,  B33Y40/20 ,  B33Y10/00 ,  B33Y70/10 ,  B29K101/12 ,  B29K307/04

CPC classification number: B29C64/118 ,  B29C64/188 ,  B33Y40/20 ,  B29K2101/12 ,  B29K2307/04 ,  B33Y10/00 ,  B33Y70/10

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

公开(公告)号：US20230191651A1

公开(公告)日：2023-06-22

申请号：US17553581

申请日：2021-12-16

Applicant: Northrop Grumman Systems Corporation

Inventor： Benjamin W. Garcia ,  Eric G. Barnes

IPC: B28B1/00 ,  B33Y10/00 ,  B33Y40/20 ,  B33Y30/00 ,  B29C64/118 ,  B29C64/30 ,  B28B11/04 ,  B28B11/24

CPC classification number: B28B1/001 ,  B28B11/04 ,  B28B11/243 ,  B29C64/30 ,  B29C64/118 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/20 ,  B29K2101/10

Abstract: A method of forming a structure comprising a continuous fiber material comprises continuously feeding, through a continuous fiber nozzle assembly of an additive manufacturing tool, a feed material comprising a continuous fiber material and a thermoset resin material, heating or cooling the feed material to maintain a temperature of the feed material to a temperature sufficient to tackify the feed material and at least partially cure the feed material and initiate adhesion of the feed material on a build platform or a previously formed portion of a structure, and moving the continuous fiber nozzle assembly in three dimensions while depositing the feed material on the build platform or the previously formed portion of the structure to form the structure comprising the continuous fiber material extending in three dimensions. Related methods of forming a composite structure, and related tools for additively manufacturing a structure are disclosed.

公开(公告)号：US11167483B2

公开(公告)日：2021-11-09

申请号：US16380131

申请日：2019-04-10

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Pedro A. Gonzalez ,  Todd L. Szallay ,  Steven J. Floyd ,  Sung S. Park ,  Brett G. Morham ,  Cody J. Brown ,  Reese R. Allen ,  Ryan L. Bischoff

IPC: B29C64/118 ,  B29C64/209 ,  B33Y30/00 ,  B29C64/20 ,  B33Y10/00

Abstract: A 3D printing machine for fabricating high performance 3D integrated composite structures, where the machine includes a robot having a base portion, a robot arm and a rotatable connector secured to the arm opposite to the base portion, at least one source of an extrudable material, and an end-effector mounted to the rotatable connector and including at least one extruder module for extruding the extrudable material. The extruder module includes a nozzle assembly for extruding heated material out of the end-effector, and the end-effector is rotatable relative to the structure by the rotatable connector so that the nozzle assembly can be oriented normal to the part in different orientations without significantly changing a pose of the robot.

公开(公告)号：US20200324472A1

公开(公告)日：2020-10-15

申请号：US16380328

申请日：2019-04-10

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Pedro A. Gonzalez ,  Todd L. Szallay ,  Steven J. Floyd ,  Sung S. Park ,  Brett G. MORHAM ,  Cody J. Brown ,  Reese R. Allen ,  Ryan L. Bischoff

IPC: B29C64/209 ,  B29C64/118 ,  B29C64/241

Abstract: A printing machine for fabricating high performance 3D integrated composite structures. The machine includes a robot having a base portion, a robot arm and an end joint secured to the arm opposite to the base portion, at least one source of an extrudable material, and an end-effector mounted to the end joint. The end-effector includes at least one extruder module for extruding the extrudable material and a rotary assembly, where the extruder module includes a nozzle assembly for extruding heated material out of the end-effector. The extruder module is mounted to the rotary assembly and the rotary assembly is rotatable so as to rotate the nozzle assembly relative to the part without rotating the end-effector.

公开(公告)号：US10207426B2

公开(公告)日：2019-02-19

申请号：US14883282

申请日：2015-10-14

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Daniel J. Braley ,  Anthony M. Tamayo ,  Eric G. Barnes

IPC: B29B13/00 ,  B29B13/02 ,  B29C70/08 ,  B29D99/00 ,  B33Y70/00 ,  B29C64/106

Abstract: A system and method for producing a uniform continuous fiber filament. The system and method include a fiber tow with an axial magnet attached to an end of the fiber tow, a polymer tube, and a radial magnet that fits around a circumference of the polymer tube. The radial and axial magnets are used to feed the fiber tow through the polymer tube using magnetic forces to create the uniform continuous fiber filament.