US 12,134,226 B2
Systems and methods of additive manufacturing
Maxwell Joseph Johnson, Hayden, ID (US); Nathan Andrew Stranberg, Post Falls, ID (US); Ryan C. Stockett, Spokane, WA (US); Mikel Negugogor, Logan, UT (US); Chase Bosman, Post Falls, ID (US); Logan Lalonde, Post Falls, ID (US); Stephen Tyler Wilson, Coeur D'Alene, ID (US); and Christopher Losee, Coeur d'Alene, ID (US)
Assigned to CONTINUOUS COMPOSITES INC., Coeur D'Alene, ID (US)
Filed by Continuous Composites Inc., Coeur d'Alene, ID (US)
Filed on Oct. 18, 2022, as Appl. No. 18/047,496.
Claims priority of provisional application 63/262,802, filed on Oct. 20, 2021.
Prior Publication US 2023/0124104 A1, Apr. 20, 2023
Int. Cl. B29C 64/118 (2017.01); B33Y 10/00 (2015.01); B33Y 70/10 (2020.01); B33Y 80/00 (2015.01); B29K 105/08 (2006.01)
CPC B29C 64/118 (2017.08) [B33Y 10/00 (2014.12); B33Y 70/10 (2020.01); B33Y 80/00 (2014.12); B29K 2105/08 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method of additively manufacturing a joint between structural branches within an object using a composite material, comprising:
depositing a first plurality of paths of the composite material within a first layer at the joint, each of the first plurality of paths having:
a center portion at a center of the joint;
a first portion integral with the center portion and extending away from the center portion to at least partially form a first branch of the joint together with the first portions of a remainder of the first plurality of paths; and
a second portion integral with the center portion and extending away from the center portion opposite the first portion to at least partially form a second branch of the joint together with the second portions of a remainder of the first plurality of paths; and
depositing a second plurality of paths of the composite material primarily within the first layer at the joint, each of the second plurality of paths having:
a center portion at the center of the joint; and
a first portion integral with the center portion and extending away from the center portion to at least partially form a third branch of the joint together with the first portions of a remainder of the second plurality of paths,
wherein the second plurality of paths cross over and are bonded to the first plurality of paths at the center of the joint to form spaced-apart bumps that extend into a second layer at the joint
depositing at least one additional path of the composite material within the second layer at the joint
wherein after deposition of the first plurality of paths, the second plurality of paths, and the at least one additional path within the second layer, each of the first branch, the second branch, and the center of the joint have an equal number of layers of deposited composite material.