Automated Manufacture Of 3D Objects From Composite Material

Abstract

Described is an apparatus for the manufacture of 3 D objects from composite materials. The apparatus includes an adjustable support platform formed by a plurality of individually adjustable support columns; at least one material extrusion nozzle configured to extrude a composite material of a manufactured 3 D object; and at least one robotic arm configured to operate a plurality of end-effector tools. The at least one robotic arm maintains at least an extrusion nozzle perpendicular to surface of the extruded 3 D object's surface segment.

We claim: 
     
         1 . An apparatus for the manufacture of 3D objects from composite materials, comprising:
 an adjustable support platform formed by a plurality of individually adjustable support columns;   at least one material extrusion nozzle configured to extrude a composite material of a manufactured 3D object; and   at least one robotic arm configured to operate a plurality of end-effector tools;   wherein at least one robotic arm maintains at least an extrusion nozzle perpendicular to surface of the extruded 3D object's surface segment.   
     
     
         2 . The apparatus of  claim 1 , wherein the material extrusion nozzle is configured to extrude the composite material comprising a multistrand filament with a thixotropic matrix material surrounding the multistrand filament. 
     
     
         3 . The apparatus of  claim 1 , wherein the individually adjustable support columns are terminated by an object receiving surface configured to accept the desired orientation in space. 
     
     
         4 . The apparatus of  claim 3 , wherein an object receiving surface terminates each adjustable support column, and wherein the object receiving surface rotates 340 degrees in any direction concerning the symmetry axis (Z-axis) of the adjustable support. Column. 
     
     
         5 . The apparatus of  claim 1 , wherein the robotic arm holding the composite material extrusion nozzle is configured to follow the contour of the spanning in the air 3D object surface element. 
     
     
         6 . The apparatus of  claim 1 , wherein at least one robotic arm is configured to operate a plurality of exchangeable end-effector tools. 
     
     
         7 . The apparatus of  claim 5 , wherein a control computer receives the contour of the 3D object surface segment spanning in the air from a CAD system. 
     
     
         8 . The apparatus of  claim 1 , wherein at least one robotic arm displaces the material extrusion nozzle and maintains the extrusion nozzle perpendicular to surface segment of the extruded 3D object. 
     
     
         9 . The apparatus of  claim 1 , wherein a control computer dynamically changes the extrusion nozzle angle to keep it perpendicular to the extruded 3D object's surface segment. 
     
     
         10 . The apparatus of  claim 1 , wherein the extrusion nozzle cross-section is one of a group of cross-sections consisting of a round, rectangular, and hexagonal cross-section. 
     
     
         11 . The apparatus of  claim 1 , wherein the extrusion nozzle covers a multistrand filament with an additional coating and wherein the additional coating enhances the strength of the multistrand filament. 
     
     
         12 . The apparatus of  claim 1 , wherein at least one robotic arm is configured to reach every point of a manufactured 3D object. 
     
     
         13 . The apparatus of  claim 1 , wherein the manufacture of a 3D object does not require the use of mandrels or mold.