# US 12,179,269 B2 · Motion technique for deposition processes to manufacture leading edge protective sheaths > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,179,269 B2 - Document ID: US12179269B2 - Status: Granted - Kind: B2 - Application number: 17/329,811 - Filed: 2021-05-25 - Published: 2021-12-30 - Granted: 2024-12-31 - Earliest claimed: 2020-06-25 - Assignees: The United States of America as represented by the Secretary of the Army - Applicants: U.S. Army Combat Capabilities Development Command, Army Research Laboratory - Inventors: Isaac M. Nault; Kenneth W. Young; Gehn D. Ferguson; Aaron T. Nardi - Web page: https://patentgrep.com/patent/US12179269B2 ## CPC - B22F 10/38: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures - B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] - B22F 10/30: Process control - B22F 10/34: of powder characteristics, e.g. density, oxidation or flowability - B22F 10/80: Data acquisition or data processing - B22F 10/85: for controlling or regulating additive manufacturing processes - B33Y 50/02: for controlling or regulating additive manufacturing processes - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - B29C 64/112: using individual droplets, e.g. from jetting heads - B33Y 10/00: Processes of additive manufacturing - F03D 1/0675: {of the blades} - Y02P 10/25: Process efficiency - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - F03D: WIND MOTORS - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method of determining a tool path for an additive deposition on a surface, the method including receiving primary edges data of the surface of a three-dimensional (3D) object; calculating a number of raster lines for applying an additive deposition on the surface; mapping a raster pattern to the surface of the 3D object; calculating surface normal and rotational angles along the raster lines; calculating a nozzle velocity of an additive application used for producing the additive deposition on the surface; identifying curvature effects of the 3D object; and establishing an order of performing passes of the additive deposition on the surface based on a selected direction for performing the additive deposition and a consideration of a residual stress profile of a resulting deposit. ## Claims ### Claim 1 A method of determining a tool path for an additive deposition on a surface, the method comprising: receiving primary edges data of the surface of a three-dimensional (3D) object; calculating a number of raster lines for applying an additive deposition on the surface; mapping a raster pattern to the surface of the 3D object; calculating surface normal and rotational angles along the raster lines; calculating a nozzle velocity of an additive application used for producing the additive deposition on the surface; identifying curvature effects of the 3D object; and establishing an order of performing passes of the additive deposition on the surface based on a selected direction for performing the additive deposition and a consideration of a residual stress profile of a resulting deposit. ### Claim 2 (depends on 1) The method of claim 1, wherein the primary edges comprise a first side edge, a second side edge, a first trailing edge, a second trailing edge, and a leading edge. ### Claim 3 (depends on 2) The method of claim 2, wherein the number of raster lines is calculated by dividing a length of the first side edge by a baseline line spacing parameter and rounding to a nearest integer. ### Claim 4 (depends on 1) The method of claim 1, wherein the raster pattern is mapped to the surface of the 3D object by aligning the primary edges and allowing remaining raster lines to elastically deform therebetween. ### Claim 5 (depends on 1) The method of claim 1, wherein the nozzle velocity of the additive deposition is calculated by: local ⁢ ⁢ speed = baseline ⁢ ⁢ speed × number ⁢ ⁢ of ⁢ ⁢ passes × baseline ⁢ ⁢ thickness ⁢ ⁢ per ⁢ ⁢ pass local ⁢ ⁢ presecribed ⁢ ⁢ thickness × baseline ⁢ ⁢ line ⁢ ⁢ spacing local ⁢ ⁢ line ⁢ ⁢ spacing . ### Claim 6 (depends on 5) The method of claim 5, comprising correcting the curvature effects by: calculating a compensation factor that is a function of a local radius of curvature of the surface; and using the compensation factor to determine the nozzle velocity. ### Claim 7 (depends on 1) The method of claim 1, comprising correcting the curvature effects by: calculating a curvature corrected surface of the 3D object; and mapping the raster pattern to the curvature corrected surface instead of an actual surface of the 3D object. ### Claim 8 (depends on 1) The method of claim 1, comprising correcting the curvature effects by mapping the raster pattern to each new surface of the 3D object that is generated after deposition of each layer on the surface. ### Claim 9 (depends on 1) The method of claim 1, wherein the establishing of the order of performing the additive deposition on the surface comprises beginning with a widest layer and continuing inward on the surface. ### Claim 10 (depends on 1) The method of claim 1, wherein the establishing of the order of performing the additive deposition on the surface comprises beginning with a narrowest layer and continuing outward on the surface. ### Claim 11 A machine-readable storage medium comprising computer-executable instructions that when executed cause a processor of a robotic additive applicator device to: receive primary edges data of a surface of a three-dimensional (3D) object; calculate a number of raster lines for applying an additive deposition on the surface; map a raster pattern to the surface of the 3D object; calculate surface normal and rotational angles along the raster lines; calculate a nozzle velocity of an additive application used for producing the additive deposition on the surface; identify curvature effects of the 3D object; and establish an order of performing passes of the additive deposition on the surface based on a selected direction for performing the additive deposition and a consideration of a residual stress profile of a resulting deposit wherein the machine-readable storage medium is limited to non-transitory mediums. ### Claim 12 (depends on 11) The machine-readable storage medium of claim 11, wherein the primary edges comprise a first side edge, a second side edge, a first trailing edge, a second trailing edge, and a leading edge. ### Claim 13 (depends on 12) The machine-readable storage medium of claim 12, wherein the number of raster lines is calculated by dividing a length of the first side edge by a baseline line spacing parameter and rounding to a nearest integer. ### Claim 14 (depends on 11) The machine-readable storage medium of claim 11, wherein the raster pattern is mapped to the surface of the 3D object by aligning the primary edges and allowing remaining raster lines to elastically deform therebetween. ### Claim 15 (depends on 11) The machine-readable storage medium of claim 11, wherein the nozzle velocity of the additive deposition is calculated by: local ⁢ ⁢ speed = baseline ⁢ ⁢ speed × number ⁢ ⁢ of ⁢ ⁢ passes × baseline ⁢ ⁢ thickness ⁢ ⁢ per ⁢ ⁢ pass local ⁢ ⁢ presecribed ⁢ ⁢ thickness × baseline ⁢ ⁢ line ⁢ ⁢ spacing local ⁢ ⁢ line ⁢ ⁢ spacing . ### Claim 16 (depends on 15) The machine-readable storage medium of claim 15, wherein the instructions, when executed, further cause the processor to correct the curvature effects by: calculating a compensation factor that is a function of a local radius of curvature of the surface; and using the compensation factor to determine the nozzle velocity. ### Claim 17 (depends on 11) The machine-readable storage medium of claim 11, wherein the instructions, when executed, further cause the processor to correct the curvature effects by: calculating a curvature corrected surface of the 3D object; and mapping the raster pattern to the curvature corrected surface instead of an actual surface of the 3D object. ### Claim 18 (depends on 11) The machine-readable storage medium of claim 11, wherein the instructions, when executed, further cause the processor to correct the curvature effects by mapping the raster pattern to each new surface of the 3D object that is generated after deposition of each layer on the surface. ### Claim 19 (depends on 11) The machine-readable storage medium of claim 11, wherein the establishing of the order of performing the additive deposition on the surface comprises beginning with a widest layer and continuing inward on the surface. ### Claim 20 (depends on 11) The machine-readable storage medium of claim 11, wherein the establishing of the order of performing the additive deposition on the surface comprises beginning with a narrowest layer and continuing outward on the surface.