SYSTEMS AND METHODS FOR CONTROLLING ADDITIVE MANUFACTURING
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 cause the additive manufacturing machine to discharge a path of composite material. The processor may also be configured to execute the computer-executable instructions to make a comparison of an actual discharge location of the path of composite material to a desired discharge location, and to selectively cause the additive manufacturing machine to abort fabrication of the structure or to adjust discharge parameters based on the comparison.
1 . A system for additively manufacturing a structure, comprising:
an additive manufacturing machine;
a memory having computer-executable instructions stored thereon; and
a processor configured to execute the computer-executable instructions to:
cause the additive manufacturing machine to discharge a path of composite material;
make a comparison of an actual discharge location of the path of composite material to a desired discharge location; and
selectively cause the additive manufacturing machine to abort fabrication of the structure or to adjust a discharge parameter based on the comparison.
2 . The system of claim 1 , wherein the processor is further configured to execute the computer-executable instructions to cause the additive manufacturing machine to abort fabrication of the structure when the actual discharge location falls outside of a first tolerance zone located around the desired discharge location.
3 . The system of claim 2 , wherein the processor is further configured to execute the computer-executable instructions to cause the additive manufacturing machine to adjust discharge parameters when the actual discharge location falls outside of a second tolerance zone located around the desired discharge location and inside of the first tolerance zone.
4 . The system of claim 1 , wherein:
the composite material includes a continuous fiber at least partially coated in a matrix; and
the actual discharge location includes a location of an axis of the continuous fiber.
5 . The system of claim 4 , wherein the actual discharge location further includes at least one of a cross-sectional shape and size of the matrix surrounding the continuous fiber.
6 . The system of claim 1 , wherein the discharge parameter includes a head trajectory.
7 . The system of claim 1 , wherein the discharge parameter includes a matrix discharge rate.
8 . The system of claim 1 , wherein the discharge parameter includes a matrix cure rate.
9 . The system of claim 1 , wherein:
the additive manufacturing machine includes a scanner configured to generate images of the path of composite material during discharge; and
the processor is further configured to execute the computer-executable instructions to determine the actual discharge location based on the images.
10 . A method of fabricating a structure with an additive manufacturing machine, the method comprising:
causing the additive manufacturing machine to discharge a path of composite material;
making a comparison of an actual discharge location of the path of composite material to a desired discharge location; and
selectively causing the additive manufacturing machine to abort fabrication of the structure or to adjust a discharge parameter based on the comparison.
11 . The method of claim 10 , wherein selectively causing the additive manufacturing machine to abort fabrication of the structure includes causing the additive manufacturing machine to abort fabrication of the structure when the actual discharge location falls outside of a first tolerance zone located around the desired discharge location.
12 . The method of claim 11 , wherein selectively causing the additive manufacturing machine to adjust discharge parameters includes causing the additive manufacturing machine to adjust discharge parameters when the actual discharge location falls outside of a second tolerance zone located around the desired discharge location and inside of the first tolerance zone.
13 . The method of claim 10 , wherein:
the composite material includes a continuous fiber at least partially coated in a matrix; and
the actual discharge location includes a location of an axis of the continuous fiber.
14 . The method of claim 13 , wherein the actual discharge location further includes at least one of a cross-sectional shape and size of the matrix surrounding the continuous fiber.
15 . The method of claim 10 , wherein the discharge parameter includes a head trajectory.
16 . The method of claim 10 , wherein the discharge parameter includes a matrix discharge rate.
17 . The method of claim 10 , wherein the discharge parameter includes a matrix cure rate.
18 . The method of claim 10 , further including generating images of the path of composite material during discharge, wherein determining the actual discharge location includes determining the actual discharge location based on the images.
19 . A non-transitory computer readable medium containing computer-executable programming instructions for performing a method of additively manufacturing a structure, the method comprising:
causing an additive manufacturing machine to discharge a path of composite material, including a continuous fiber at least partially coated in a matrix;
making a comparison of an axis location of the continuous fiber and at least one of a cross-sectional shape and size of the matrix surrounding the continuous fiber to a desired discharge location;
causing the additive manufacturing machine to abort fabrication of the structure when one of the axis location and the at least one of the cross-sectional shape and size of the matrix surrounding the continuous fiber falls outside of a first tolerance zone located around the desired discharge location; and
causing the additive manufacturing machine to adjust a discharge parameter when one of the axis location and the at least one of the cross-sectional shape and size of the matrix surrounding the continuous fiber falls outside of a second tolerance zone located around the desired discharge location and inside of the first tolerance zone.
20 . The non-transitory computer readable medium of claim 19 , wherein the discharge parameter includes at least one of a head trajectory, a matrix discharge rate, and a matrix cure rate.