System and method for additive manufacturing of an object with foam infill material

A system for additive manufacturing of an object, the system comprising:

• a first nozzle to deposit body material to form a shell portion of the object;
• a second nozzle to deposit a foam infill material inside an interior of the shell portion of the object;
• a processor communicatively connected to a memory storing instructions, the instructions when executed by the processor, cause the processor to:
• determine the shell portion of the object using the three-dimensional model of the object;
• determine one or more locations in the shell portion for providing access to the interior of the shell portion;
• determine an amount of a foam infill material needed to fill the interior of the shell portion;
• fabricate the shell portion of the object;
• deposit the amount of the foam infill material at the one or more determined locations to fill the interior of the shell portion;
• and
• fabricate the shell portion of the object to complete fabrication of the object;
• a nozzle control unit to operate the first nozzle and the second nozzle for manufacturing the object;
• and
• a camera to provide positioning information associated with the first nozzle and the second nozzle and to enable quality control measures, wherein the quality control measures enabled by the camera comprises, determining, via an image analysis, that an excess amount of the foam infill material has been deposited.

A non-transitory computer readable storage media coupled to a processor and having instructions storing thereon which, when executed by the processor, cause the processor to perform operations for additive manufacturing of an object, the operations comprising:

• determining a shell portion of the object using a three-dimensional model of the object, including determining a first set of spatial movement instructions to fabricate the shell portion of the object;
• determining one or more locations in the shell portion for providing access to an interior of the shell portion;
• determining an amount of foam infill material needed to fill the interior of the shell portion, including determining a second set of spatial movement instructions to deposit the foam infill material inside the interior of the object shell portion;
• fabricating the shell portion of the object according to the first set of spatial movement instructions using a first nozzle;
• depositing the amount of the foam infill material at the one or more determined locations to fill the interior of the shell portion according to the second set of spatial movement instructions using a second nozzle;
• deploying a material removal arm to remove excess amount of the foam infill material;
• fabricating the shell portion of the object to complete fabrication of the object;
• and
• providing, by a camera, positioning information associated with the first nozzle and the second nozzle and to enable quality control measures, wherein the quality control measures enabled by the camera comprises, determining, via an image analysis, that an excess amount of the foam infill material has been deposited.