Apparatus and methods for fabricating components
An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.
1. An additive manufacturing method, comprising:
receiving a thermoplastic material with an additive manufacturing apparatus;
conveying the thermoplastic material through a thermoplastic material guide;
guiding the thermoplastic material to a position ahead of a compression roller, the compression roller being secured to a lower portion of an applicator head; and
compressing the thermoplastic material with the compression roller while displacing the applicator head, wherein the compression roller is secured to the applicator head by a bracket extending below the applicator head.
2. The method of claim 1 , wherein the thermoplastic material includes a reinforcing fiber material.
3. The method of claim 1 , wherein compressing the thermoplastic material with the compression roller is performed while the thermoplastic material is in a pliable state due to an elevated temperature of the thermoplastic material.
4. The method of claim 1 , wherein the compression roller is positioned between an underside of the applicator head and a surface of a worktable while the thermoplastic material is guided to the position ahead of the compression roller.
5. The method of claim 1 , wherein conveying the thermoplastic material includes supplying the thermoplastic material from an upstream source to the thermoplastic material guide, the thermoplastic material guide extending outside of the applicator head.
6. The method of claim 5 , wherein the thermoplastic material guide includes an interior for guiding the thermoplastic material, a portion of the interior outside of the applicator head forming an angle with respect to a vertical direction.
7. The method of claim 1 , wherein, after exiting the material guide, the thermoplastic material is deposited on a surface formed by a worktable.
8. An additive manufacturing method, comprising:
supplying a thermoplastic material to a material guide;
guiding the thermoplastic material, via the material guide, to a position ahead of a path of a compression roller secured to an applicator head; and
compressing the thermoplastic material with the compression roller such that a thickness of the thermoplastic material is reduced by the compression, wherein the compression roller is secured to the applicator head by a bracket extending below the applicator head.
9. The method of claim 8 , wherein the thermoplastic material is provided with a fiber material.
10. The method of claim 8 , wherein the position of the thermoplastic material extends below the applicator head while the thermoplastic material is compressed by the compression roller.
11. The method of claim 8 , wherein the compression roller is positioned between the applicator head and a surface of a worktable while depositing the thermoplastic material.
12. The method of claim 8 , wherein the material guide extends to a height above the compression roller while the thermoplastic material is guided to the position ahead of the path of the compression roller.
13. The method of claim 8 , further including conveying the thermoplastic material with the material guide along a path having a portion that forms an angle with respect to a vertical direction.
14. The method of claim 8 , wherein guiding the thermoplastic material includes passing the thermoplastic material through an opening at a distal end portion of the material guide.
15. An additive manufacturing method, comprising:
receiving a thermoplastic material with an additive manufacturing apparatus;
guiding the thermoplastic material with the additive manufacturing apparatus to a position ahead of a path of a roller secured to an applicator head; and
compressing the thermoplastic material with the roller while the thermoplastic material is in a pliable state due to an elevated temperature of the thermoplastic material, wherein the roller is secured to the applicator head by a bracket extending below the applicator head.
16. The method of claim 15 , wherein, while guiding the thermoplastic material, the roller is positioned between an underside of the applicator head and a surface of a worktable.
17. The method of claim 15 , further including supplying the thermoplastic material from a source to a thermoplastic material guide of the additive manufacturing apparatus, wherein the thermoplastic material guide includes a hollow interior sized to receive the thermoplastic material, a portion of the interior forming an angle with respect to a vertical direction.
18. The method of claim 17 , wherein the thermoplastic material is supplied with a reinforcing fiber material.
19. The method of claim 15 , wherein the position ahead of the path of the roller is located on a worktable and the roller is positioned between the applicator head and the worktable while the thermoplastic material is guided to the position ahead of the path of the roller.