# US 12,759,236 B2 · Additive manufacturing system incorporated with artificial intelligence

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- Number: US 12,759,236 B2
- Document ID: US12759236B2
- Status: Granted
- Kind: B2
- Application number: 18/339,043
- Filed: 2023-06-21
- Published: 2023-12-21
- Granted: 2026-10-13
- Earliest claimed: 2022-06-21
- Assignees: NDSU Research Foundation
- Applicants: Ndsu Research Foundation
- Inventors: Chad Ulven; Md Atikur Rahman; Md. Zahirul Islam; Luke R. Gibbon
- Web page: https://patentgrep.com/patent/US12759236B2

## CPC

- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B29C 64/10: Processes of additive manufacturing
- B33Y 10/00: Processes of additive manufacturing
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- C08J 5/243: {using carbon fibres}
- B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C 70/38: Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)}
- 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)
- 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
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)

## Abstract

Commercial additive manufacturing with continuous reinforcement produces parts with low fiber volume fraction and limited printing parameters. Mechanical properties of 3D printed products are improved with high fiber volume fraction. This technology solves, at least, the problem of undetected print fails of currently available technology. Applicator engineering solves the issue of poor interlaminar adhesion. The incorporation of elevated temperature control and real-time monitoring helps solve dimensional errors that happen due to postcuring. This technology mitigates and prevents print failures which will save time and material and improve printing efficiency. Ultrasonic vibration reduces the void in the print by better dispersion of resin.

## Claims

### Claim 1

A method of 3D printing comprising:
generating a variable prepreg by partially curing pre-impregnated fiber tow via a curing chamber comprising a plurality of U.V. light sources;
using a transparent applicator and the variable prepreg such that U.V. light further cures the prepreg to form a 3D printed composite; and
mechanically or ultrasonically inducing vibration(s) while generating the variable prepreg and/or forming the 3D printed composite to create a surface layer finish varied in texture and/or quality for different parts of the 3D printed composite.

### Claim 2 (depends on 1)

The method of 3D printing of claim 1, comprising varying a fiber volume fraction to alter the surface layer finish of the 3D printed composite.

### Claim 3 (depends on 1)

The method of 3D printing of claim 1, further comprising varying an amount of curing on the prepreg to alter the surface layer finish of the 3D printed composite.

### Claim 4 (depends on 1)

The method of 3D printing of claim 1, further comprising varying a U.V. intensity while printing to alter the surface layer finish of the 3D printed composite.

### Claim 5 (depends on 1)

The method of 3D printing of claim 1, further comprising generating a printing path using a machine learning artificial intelligence (A.I.) program.

### Claim 6 (depends on 1)

The method of 3D printing of claim 1, wherein the generating of the prepreg occurs after the 3D printed composite is designed and print paths have been determined.

### Claim 7 (depends on 6)

The method of 3D printing of claim 6, further comprising feeding data related to the surface layer finish and interlaminar adhesion to the A.I. program.

### Claim 8 (depends on 7)

The method of 3D printing of claim 7, wherein an active camera looks at a printing point and feeds the data to the A.I. program.

### Claim 9 (depends on 8)

The method of 3D printing of claim 8, wherein the A.I. program uses image processing to actively detect an imperfection selected from the group consisting of: voids, print failure, and uneven surfaces.

### Claim 10 (depends on 9)

The method of 3D printing of claim 9, further comprising heuristically improving print parameters and a print line for the different parts of the 3D printed composite by continually running the A.I. program during 3D printing.

### Claim 11 (depends on 10)

The method of 3D printing of claim 10, further comprising using the data to repair the imperfection during the next layer by varying said print parameters.

### Claim 12 (depends on 6)

The method of 3D printing of claim 6, further comprising enabling the printer to print with neat resin on an outer surface of the 3D printed composite and to print composite in the core of the 3D printed composite.

### Claim 13 (depends on 1)

The method of 3D printing of claim 1, further comprising utilizing a laser cutting torch to cut the 3D printed composite on a layer-by-layer basis.