Apparatus and method for applying elongate fibrous tows

Abstract

A presser foot device and system including a presser foot device for forming and applying an elongated fiber tow, wherein the presser foot device includes a foot surface including a straight foot segment, a groove including a flared end and defining a groove mid-plane, and a foot shaft housing characterized by a rotational axis of the foot shaft that is orthogonal to the straight foot segment and is included in the groove mid-plane.

Description

Technical Field

[0001] The present invention relates to systems and methods for forming elongated fiber tows, delivering the elongated fiber tows to a surface, and forming a fiber-reinforced plastic composite object including one or more fiber tows. Background Art

[0002] Fiber-reinforced plastics (FRPs), also known as fiber-reinforced polymers, such as carbon fiber-reinforced plastics (CFRPs), are widely used materials for lightweight structures, ranging from sports equipment to automotive components to aircraft structures. Methods for manufacturing FRPs include depositing fiber tows (e.g., prepreg tows, such as tapes) onto a substrate. Deposition is performed, for example, by a robot (e.g., a manipulator including a tape-dispensing end-effector for additive manufacturing). The deposition tape imposes constraints on one or more of the following: the speed of tape deposition, the trajectory described by the deposition end-effector, the radius of curvature of the trajectory, the amount of binder polymer used, the amount of air trapped in the FRP, the fiber volume fraction within the FRP, the deposition process temperature, the viscosity of the polymer, the geometry of the deposited layer (e.g., defined by the dimensions of the deposited layer (e.g., defined by one or more of the length, width, and height of the deposited layer)), and the staggering, juxtaposition, and stacking pattern of the tapes (e.g., tape layers). Therefore, there is a need for fiber tows (e.g., prepreg tows) that can be deposited at higher speeds and with higher uniformity than can be achieved using conventional tape laying techniques. Systems and methods for manufacturing fiber tows are needed. There is also a need for systems and methods for delivering and applying fiber tows to a surface to form an object. There is also a need for laying fiber tows over a trajectory including curves with a small radius of curvature and having improved and diverse fiber layout patterning capabilities. Summary of the Invention

[0003] One problem in the field of fiber reinforced plastics relates to the speed at which one or more fiber rovings can be deposited to form a layout. Another problem relates to the precision of the layout. Another problem relates to the fiber density within a given volume that can be achieved to impart strength to the resulting composite material. Therefore, it is an object of the present disclosure to provide embodiments of systems and methods for manufacturing fiber tows. It is also an object of the present disclosure to provide systems and methods for conveying and applying fiber tows to a surface to form an object. It is also an object of the present disclosure to provide methods for laying fiber tows over a trajectory that includes a curve with a small radius of curvature.

[0004] One embodiment of the present disclosure includes a presser foot device for applying a slender fiber bundle to the surface of an object, the device comprising: a foot surface, which is used to press the fiber bundle onto the surface of the object, the foot surface including a straight foot section for pressing the fiber bundle onto the surface of the object, the straight foot section including a rear end and a front end, the rear end and the front end defining a front direction Fx from the rear end to the front end; and a groove, which includes a left lip edge and a right lip edge for guiding the bundle to the foot surface, the groove defining the groove midplane as a planar portion along the center line of the groove and extending until between the left lip edge and the right lip edge of the groove, the groove being joined to the front end of the straight foot section and oriented at an elevation angle relative to the straight foot section, wherein the groove includes a flared end engaged with the foot surface.

[0005] For example, a portion of the groove has an elevation angle of 90°. For example, the groove includes a flared inlet at the groove entrance, the groove entrance being located at an end opposite the flared end. For example, the foot surface includes: a first toe surface located on a first side of the groove's midplane and oriented at a first elevation angle and a first azimuth angle away from the frontal direction Fx; and a second toe surface located on a second side of the groove's midplane and oriented at a second elevation angle and a second azimuth angle away from the frontal direction Fx, wherein the first azimuth angle and the second azimuth angle are within a range of 30° to 90° relative to the frontal direction Fx. For example, the first azimuth angle and the second azimuth angle are approximately 90° relative to the frontal direction Fx.

[0006] For example, the first toe surface and the second toe surface are coplanar. For example, the flared end includes a chamfer having an elevation angle within a range of 30° to 70° relative to the frontal direction Fx. For example, the flared end includes a rounded corner that joins the groove to the straight leg segment. For example, the foot surface is planar. For example, when viewed in a cross-section taken along a YZ plane orthogonal to the straight leg segment, the foot surface includes one or more elevated contour portions facing the object surface, the elevated contour portions rising away from the object surface in the Z direction relative to the straight leg segment. For example, one or more of the one or more elevated contour portions form an elevated curve. For example, one or more of the one or more elevated contour portions form an elevated straight line. For example, the foot surface includes an orientation section of a truncated hollow body of revolution, the axis of the truncated hollow body of revolution being included in the midplane of the groove, wherein the orientation section is included in the range of 180° to 320°. For example, the device includes a hollow foot shaft, the axis of which is included in the midplane of the groove. For example, the device includes a foot pinion, the axis of which is included in the midplane of the groove. For example, the device comprises a castor wheel, the axis of which is included in the mid-plane of the groove.

[0007] For example, the foot surface includes a first material within a first section proximal to the front end and a second material within a second section distal to the front end, wherein the thermal conductivity of the second material is at most half the thermal conductivity of the first material. For example, the foot surface includes a heat sink. For example, the foot surface includes a heat sink that forms a second section surrounding the first section proximal to the groove. For example, the flared end includes a first flared end portion that is proximal to the groove, rises a distance from the foot surface, and is separated from the heat sink portion included in the foot surface by a second section, wherein the second section forms a thermally insulating portion between the first flared end portion and the foot surface.

[0008] For example, the cross-section of the groove includes one or more pairs of symmetrically opposed circular profile segments relative to the midplane, the symmetrically opposed circular profile segments being included at a groove depth that is greater than or equal to the groove depth radius of the largest circular profile segment. For example, the cross-section of the groove includes one or more U-shaped groove cross-sections that are scaled down into the groove. For example, the groove includes a cross-section that includes two or more straight edges joined by a rounded corner. For example, the distance between the first lip of the groove and the second lip of the groove is included in the range of 0.2 mm to 2 mm, for example, included in the range of 0.2 mm to 1 mm.

[0009] One embodiment of the present disclosure includes a system for applying an elongated fiber tow to a surface of an object, the system comprising a presser foot device. For example, the presser foot device comprises: a foot surface for pressing the fiber tow onto the surface of the object, the foot surface comprising a straight foot segment for pressing the fiber tow onto the surface of the object, the straight foot segment comprising a rear end and a front end, the rear end and the front end defining a frontal direction Fx from the rear end to the front end; and a groove comprising a left lip and a right lip for guiding the tow to the foot surface, the groove defining a groove midplane as a planar portion along a midline of the groove between the left lip and the right lip of the groove, the groove being engaged to the front end of the straight foot segment and oriented at an elevation angle relative to the straight foot segment, wherein the groove comprises a flared end that engages the foot surface; and a foot shaft housing characterized by a rotational axis Z of the foot shaft defining a Z axis, wherein the rotational axis Z of the foot shaft is orthogonal to the straight foot segment and is included in the groove midplane.

[0010] For example, the presser foot device includes a hollow foot shaft, the axis of which is colinear with the rotation axis Z of the foot shaft, and a portion of which forms a sliding fit within the foot shaft housing. For example, the foot shaft housing includes one or more heat sources. For example, the system includes a radiation source, which includes infrared radiation directed towards the groove. For example, the foot shaft housing includes one or more induction heating coils. For example, the axis of one or more of the induction heating coils is parallel to the axis of the rotation axis Z of the foot shaft. For example, the system includes a temperature sensor, which is included in one or more of the following: the foot shaft housing; and the presser foot device.

[0011] For example, the foot axle housing includes a cylindrical sleeve that is coaxial with the rotation axis Z of the foot axle. For example, the system includes one or more pressure roller assemblies. For example, one or more of the pressure roller assemblies include a first roller and a second roller, wherein a common tangent to the first roller and the second roller is colinear with the rotation axis Z of the foot axle. For example, one or more of the pressure roller assemblies include a first roller and a second roller, wherein one or more of the rollers include a rectangular groove located in the periphery of the rollers. For example, one or more of the pressure roller assemblies include a first roller and a second roller, wherein one or more of the rollers include a rectangular groove located in the periphery of the rollers, and wherein a cross-section of the groove intersects the rotation axis Z of the foot axle.

[0012] For example, the system includes a tow cutter assembly including an orifice and a blade, the orifice intersecting the rotation axis Z of the foot shaft. For example, the system includes a tow cutter assembly including a blade guided by a track, the blade mechanically coupled to a rotatable ring, the rotation axis of the rotatable ring being colinear with the rotation axis Z of the foot shaft.

[0013] For example, the system includes a heat exchanger housing disposed between the foot shaft housing and one or more of the one or more pressure wheel assemblies, the heat exchanger housing including a first through hole, the axis of the first through hole being colinear with the rotation axis Z of the foot shaft. For example, the heat exchanger housing is disposed between the tow cutter assembly and the foot shaft housing. For example, the heat exchanger housing includes one or more conduits. For example, the heat exchanger housing includes a conduit that forms a turning path of at least 180° around the rotation axis Z of the foot shaft. For example, the heat exchanger housing includes a second through hole, the axis of the second through hole being parallel to the rotation axis Z of the foot shaft. For example, the heat exchanger housing includes a drive shaft that is coupled to the presser foot device. For example, the heat exchanger housing forms a thermally conductive contact with the drive shaft that is coupled to the presser foot device, wherein the interface conductivity of the contact is greater than 500 W / m 2 / K. For example, the heat exchanger housing comprises a tow duct, wherein the tow duct comprises an inlet portion and an outlet portion, and wherein the axis of symmetry of the outlet portion is included in the groove midplane.

[0014] For example, a portion of the tow duct includes a converging tow duct nozzle having an outlet oriented toward the groove and wherein an axis of symmetry of the outlet is included in the groove mid-plane.

[0015] For example, the system includes one or more distance measuring detector assemblies, each of which includes a distance meter, one or more of whose measurement axes ZR are oriented in a direction parallel to the direction of the rotation axis Z of the foot shaft, wherein the distance from the measurement axis ZR of the distance measuring detector to the rotation axis Z of the foot shaft is greater than the distance from the rotation axis Z of the foot shaft to the rear end of the straight foot section and is less than 20 cm. For example, one or more of the one or more distance measuring detector assemblies includes a translation stage.

[0016] For example, the system includes a tow forming assembly including one or more sheaves wherein at least a portion of a cross-section of a groove is rectangular. For example, the cross-section of the groove of the one or more sheaves includes a V-shaped groove entrance and a rectangular groove depth.

[0017] For example, the system includes one or more infrared radiation sources directed at the tow.For example, the system includes a tow longitudinal tension detector.

[0018] For example, the system includes a slider including one or more axes. For example, one or more of the one or more axes intersects a Z-direction-extending groove midplane of the Z-direction-extending groove midplane. For example, one or more of the one or more axes includes two orthogonal axes, and the intersection of the orthogonal axes is approximately located on the Z-direction-extending groove midplane of the Z-direction-extending groove midplane.

[0019] For example, the system comprises a supporting chassis comprising a tubular clamp whose axis is parallel to the axis of rotation Z of the foot shaft.

[0020] For example, the system includes one or more of a press wheel motor coupled to one or more press wheel assemblies, a tow cutter motor coupled to a tow cutter assembly, and a foot rotation motor coupled to a presser foot device.

[0021] For example, the system includes a dispenser nozzle outlet for dispensing thermoplastic material onto a surface. For example, the system includes a dispenser nozzle extension actuator for adjusting a Z-axis position of the dispenser nozzle outlet. For example, the Z-axis position of the dispenser nozzle outlet is offset from the Z-axis position of the straight leg segment by an offset within a range of -4 mm to +4 mm.

[0022] For example, the system includes a robotic support to move at one or more spatial positions (XF, YF, ZF) and at one or more spatial orientations One or more of the position and speed of the presser foot device are configured.

[0023] For example, the system includes a computer system. For example, the computer system includes one or more of a digital processor, a computer-readable non-volatile storage device, a user interface device, a data bus connected to one or more sensors and actuators included in the system, and a communication interface device for transferring data between one or more of the digital processor, the computer-readable non-volatile storage device, the data bus, the user interface device, and one or more external systems located outside the system, the one or more external systems including one or more of the processor, the storage device, the user interface, the actuators, and the sensors.

[0024] Another embodiment of the present disclosure includes a method for applying a slender fiber bundle to the surface of an object, the method comprising: translating the slender fiber bundle entering the groove of a presser foot device to the foot surface of the presser foot device, the groove including a left lip edge, a right lip edge, and defining a groove midplane along the center line of the groove and extending until between the left lip edge and the right lip edge of the groove; guiding the fiber bundle in the groove to the flared end of the groove; bending the fiber bundle around the flared end of the groove to a straight foot section included in the foot surface of the presser foot device, wherein the straight foot section includes a rear end and a front end, the rear end and the front end defining a front direction Fx from the rear end to the front end, and the groove is joined to the front end of the straight foot section and is oriented at an elevation angle relative to the straight foot section; and pressing the fiber bundle between the straight foot section and the surface of the object.

[0025] For example, one or more of translating, guiding, bending, and pressing includes heating the fiber tow. For example, pressing includes cooling the fiber tow. For example, pressing includes a first step and a second step, the first step including heating the fiber tow, and the second step including cooling the fiber tow. For example, the method includes adjusting the electrical power delivered to one or more heat sources to heat the fiber tow. For example, the method includes rotating the presser foot device about a rotation axis Z, the rotation axis Z being orthogonal to the straight leg segment and being included in the groove midplane. For example, the method includes translating the presser foot device. For example, the method includes translating and rotating the presser foot device along a path from a starting point to an end point of the path, wherein the straight leg segment is collinear with a tangent to the path of the presser foot device, and a point of tangency with the path is included in the groove midplane. For example, the fiber tow translates within the groove at a speed equal to the speed at which the point of tangency with the path translates along the path. For example, the method includes forming an incision in the fiber tow at a location where the radius of curvature of the path is less than 2 mm, less than 3 mm, and less than 5 mm.

[0026] For example, the method includes actuating a tow cutter assembly at a position along the path that is located before the end of the path by a certain path length, the path length being equal to the length of the fiber tow from the blade of the tow cutter assembly to the front end of the right-angle segment. For example, the method includes unwinding the tow, wherein the unwinding includes rotating a presser foot device. For example, the method includes forming a measurement of the distance between the straight leg segment and the surface of the object. For example, the method includes adjusting the distance between the straight leg segment and the surface of the object. For example, the method includes adjusting the distance between the dispenser nozzle and the surface of the object. For example, the method includes adjusting the distance offset of the dispenser nozzle relative to the surface of the object based on the distance between the straight leg segment and the surface of the object.

[0027] For example, the method comprises: translating the fiber tow within the groove by a length comprised in the range of 2 mm to 30 mm; and guiding the presser foot device along a landing trajectory onto the surface of the object.

[0028] For example, the method includes forming one or more folds along the length of the fiber tow by passing the fiber band through one or more grooves comprising a rectangular cross-section. For example, forming one or more folds includes passing the fiber band through one or more grooves included in one or more sheaves. For example, the method includes obtaining a measured value of the longitudinal tension of the fiber tow from a tow longitudinal tension detector. For example, the method includes adjusting the speed of translation of the tow based on the measured value of the longitudinal tension of the fiber tow from the tow longitudinal tension detector.

[0029] Yet another embodiment of the present disclosure includes a computer-readable non-volatile storage device comprising executable instructions that, when executed by one or more processors of a system for applying elongated fiber filaments to a surface of an object, cause the system to perform at least the following operations: a) command one or more of the position and speed of a first motor so that the elongated fiber filaments translate along a groove of a presser foot device; and b) command one or more of the position and speed of a second motor coupled to the presser foot device and causing the presser foot device to rotate, wherein the presser foot device includes a foot surface for pressing the fiber filaments onto the surface of the object, the foot surface including a straight foot section for pressing the fiber filaments onto the surface of the object, wherein the straight foot section includes a rear end and a front end defining a front direction Fx from the rear end to the front end, and wherein the presser foot device rotates about an axis of rotation Z that is orthogonal to the straight foot section and is included in a midplane of the groove along a centerline of the groove, the centerline being included between a left lip and a right lip of the groove.

[0030] For example, the instructions include instructions in which the speed commanded to the first motor is a function of the speed commanded to the second motor.For example, the instructions include instructions to command a third motor coupled to the tow cutter assembly and causing the tow cutter assembly to move a blade from a first position to a second position.

[0031] For example, the instructions include instructions to adjust the speed of the first motor based on a command sent to the third motor. For example, the instructions include instructions to obtain distance meter measurement data from one or more distance meter detector assemblies. For example, the instructions include instructions to adjust the speed of the first motor based on measurements obtained from one or more distance meter detector assemblies. For example, the instructions include instructions to obtain measurement data from one or more tow longitudinal tension detectors.

[0032] For example, the instructions include instructions to adjust the speed of the first motor based on measurements taken from one or more of the one or more tow longitudinal tension sensors. For example, the instructions include instructions to adjust the relative speed of the one or more first motors based on measurements taken from one or more of the one or more tow longitudinal tension sensors. For example, the instructions include instructions to store one or more digital tool path instructions, the digital tool path instructions including one or more of the position and orientation of the presser foot assembly.

[0033] For example, the instructions include instructions to insert one or more commands for a third motor coupled to a tow cutter assembly into the digital tool path instructions based on one or more of a path length and one or more path curvatures. For example, the instructions include instructions to insert one or more commands to command unwinding of a tow, the instructions including commands to actuate a second motor. For example, the instructions include commands to one or more motors to move at one or more spatial position coordinates X. F 、Y F 、Z F and one or more instructions for configuring the position and speed of the presser foot device at one or more spatial orientation coordinates.

[0034] For example, the instructions include configuring the position of the presser foot device by commanding one or more motors based on measurements obtained from one or more range detector assemblies. and speed. For example, the instructions include instructions to adjust the distance between the straight leg segment and the object surface along the rotation axis Z to a value within the range of 0.05 mm to 1.0 mm.

[0035] For example, the instructions include instructions for translating and rotating the presser foot device along a path from a starting point of the path to an end point of the path, wherein the second motor is commanded such that the straight foot segment remains colinear with a local tangent to the path of the presser foot device, and the tangent point remains included within a segment extending from a front end of the straight foot segment to the length of the centerline of the groove.

[0036] For example, the instructions include commands for one or more motors to move at one or more spatial position coordinates (X F 、Y F 、ZF ) and one or more spatial orientation coordinates The instructions for configuring one or more of the position and speed of the dispenser nozzle are provided. For example, the instructions include instructions for commanding the dispenser nozzle extension actuator to adjust one or more of the extension position and speed of the dispenser nozzle according to one or more of the position and speed of the presser foot device. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1A is a perspective view of a presser foot assembly including a groove having a flared end.

[0038] Figure 1B is a perspective view of a presser foot assembly with a yarn bundle and a temperature sensor.

[0039] Figure 1C is a cross-sectional side view of a presser foot assembly including a flared inlet and a flared end.

[0040] Figure 1D is a bottom view of a presser foot assembly comprising: i) a first toe surface and a second toe surface, the first toe surface and the second toe surface being offset at 90° relative to a front direction of the presser foot assembly, and ii) a groove comprising a rounded rectangular cross-section.

[0041] Figure 1E is a cross-sectional side view of a presser foot assembly including a flared end including a chamfer.

[0042] Figure 1F is a bottom view of a presser foot device including a first toe surface and a second toe surface, which are arranged with an orientation offset within a range of 30° to 90° relative to a front direction of the presser foot device.

[0043] Figure 1G is a perspective view of a presser foot device comprising a third portion which is thermally insulated from a first portion adjacent to the groove by a second portion.

[0044] Figure 1H is a cross-sectional side view of a presser foot assembly wherein the flared end includes a third portion thermally insulated from a first portion adjacent the groove by a second portion.

[0045] Figure 1I is a perspective view of a presser foot device including a hollow foot shaft.

[0046] Figure 1J 2 is a bottom view of a presser foot device comprising a groove, wherein the cross section of the groove comprises one or more pairs of symmetrically opposed circular contour segments.

[0047] Figure 1Kis a bottom view of a presser foot assembly including a groove, the cross section of the groove including one or more U-shaped groove cross sections scaled down into the groove.

[0048] Figure 1L is a bottom view of a presser foot assembly including a groove having a cross section including two or more straight sides joined by a rounded corner.

[0049] Figure 1M is a perspective view of a presser foot assembly including a heat sink.

[0050] Figure 1N is a cross-sectional side view of a presser foot assembly including a heat sink.

[0051] Figure 1O is a perspective view of a presser foot assembly including one or more curved raised profile portions.

[0052] Figure 1P is a perspective view of a presser foot arrangement including one or more straight raised profile portions.

[0053] Figure 2A is a perspective view of a system for applying elongated fiber tows, the system including a pinion-driven presser foot assembly; a foot shaft housing including a heat source; and a heat exchanger housing.

[0054] Figure 2B is a perspective view of a system for applying elongated fiber tows, the system including a pulley-driven presser foot arrangement.

[0055] Figure 3A and Figure 3B is a top view of a foot spindle housing that includes one or more induction coils as a heat source for the presser foot assembly below.

[0056] Figure 4A is a front cross-section of a system for applying elongated fiber tows.

[0057] Figure 4B is a top view of a pressure wheel assembly included in a system for applying elongated fiber tows.

[0058] Figure 4C is a top-down cross-section of a heat exchanger comprising one or more conduits.

[0059] Figure 5 is a perspective view of a system for applying elongated fiber tows.

[0060] Figure 6A is a side view of the tow forming assembly.

[0061] Figure 6B 、 Figure 6C 、 Figure 6Dis a cross section of the sheave of the tow forming assembly.

[0062] Figure 6E is a cross-section of an infrared radiation source used to heat the tow being formed in the tow forming assembly.

[0063] Figure 7 is a side view of a system for applying elongated fiber tows, the system also including a slider head, a tow forming assembly, and a tow buffer.

[0064] Figure 8 is a front cross-section of a system for applying elongated fiber tows, the system also including a dispenser nozzle discharge for dispensing thermoplastic material.

[0065] Figure 9 is a perspective view of a system for applying elongated fiber tows mounted on a robotic arm.

[0066] Figure 10 is a top view of a system for applying elongated fiber tows included in an XY stage that also includes a Z-actuated object support.

[0067] Figure 11 is a block diagram of a computer system for controlling a system for applying elongated fiber tows.

[0068] Figure 12 is a block diagram of a method for applying an elongated fiber tow to a surface of an object.

[0069] Figure 13 is a block diagram of computer-readable instructions for controlling a system for applying elongated fiber tows.

[0070] Figure 14 is a top view of an object comprising a plurality of fiber tow segments.

[0071] Figure 15A 、 Figure 15B 、 Figure 15C are side views of a system for applying elongated fiber tows, each showing a landing trajectory. DETAILED DESCRIPTION

[0072] Figure 1A to Figure 1PExemplary embodiments 1001, 1001S, 1002B, 1003S, 1004B, 1005, 1006S, 1006, 1007G, 1008G, 1009G, 1010, 1011S, 1012, 1013 of a presser foot apparatus 1100 for applying an elongated fiber tow 100 are presented. For example, a presser foot device 1100 for applying an elongated fiber bundle 100 to an object surface 200 includes: a foot surface 1150, the foot surface 1150 being used to press the fiber bundle 100 onto the object surface 200, the foot surface 1150 including a straight foot section 1110 for pressing the fiber bundle 100 onto the object surface 200, the straight foot section 1110 including a rear end 1112 and a front end 1111, the rear end 1112 and the front end 1111 defining a front direction Fx from the rear end to the front end; and a groove 1130, the groove 1130 1130 includes a left lip 1141 and a right lip 1142 for directing a tow to a foot surface 1150. Groove 1130 defines a groove midplane 1130MP as a planar portion along groove midline 1130ML and extending between left lip 1141 and right lip 1142 of groove 1130. Groove 1130 is joined to front end 1111 of straight leg section 1110 and oriented at an elevation angle 1130A relative to straight leg section 1110. Groove 1130 includes a flared end 1120 that engages foot surface 1150. For example, elevation angle 1130A of a portion of groove 1130 is 90°. For example, groove 1130 includes a flared inlet 1133 located at groove inlet 1130E, which is located at an end opposite flared end 1120. In some embodiments, groove 1130 includes one or more enclosed portions that form, for example, a channel.

[0073] For example, foot surface 1150 includes a first toe surface 1161 located on a first side of groove midplane 1130MP and oriented at a first elevation angle 1161A1 and a first azimuth angle 1161A2 from frontal direction Fx; and a second toe surface 1162 located on a second side of groove midplane 1130MP and oriented at a second elevation angle 1162A1 and a second azimuth angle 1162A2 from frontal direction Fx, wherein first azimuth angle 1161A2 and second azimuth angle 1162A2 are within a range of 30° to 90° relative to frontal direction Fx. For example, first azimuth angle 1161A2 and second azimuth angle 1162A2 are approximately 90° relative to frontal direction Fx. For example, first toe surface 1161 and second toe surface 1162 are coplanar. For example, flared end 1120 includes a chamfer 1125 having an elevation angle 1125A in the range of 30° to 70° relative to frontal direction Fx. For example, flared end 1120 includes a radius 1120F that joins recess 1130 to straight leg segment 1110. For example, foot surface 1150 is planar. For example, when viewed in a cross-section taken along a YZ plane orthogonal to straight leg segment 1110, foot surface 1150 includes one or more elevated profile portions 1171, 1172 facing toward object surface 200. These elevated profile portions 1171, 1172 are elevated away from object surface 200 in the Z direction relative to straight leg segment 1110.

[0074] Figure 1O is a perspective view of a presser foot device 1100 including one or more curved raised profile portions 1171, 1172. For example, one or more of the one or more raised profile portions 1171, 1172 form a raised curve 1171C, 1172C. Figure 1P 1 is a perspective view of a presser foot device 1100 including one or more straight raised contour portions 1171, 1172. For example, one or more of the one or more raised contour portions 1171, 1172 form raised straight lines 1171L, 1172L.

[0075] For example, foot surface 1150 includes an orientation segment 1150A of a truncated hollow body of revolution whose axis is included in the mid-plane 1130MP of the groove, wherein orientation segment 1150A is included in the range from 180° to 320°. For example, device 1100 includes a hollow foot shaft 1200 whose axis is included in the mid-plane 1330MP of the groove.

[0076] For example, the device includes a foot pinion 1210, the axis of which is included in the mid-plane 1330MP of the groove. For example, the foot pinion 1210 includes an aperture 1211 on its axis of rotation, for example for the passage of the fiber tow 100. For example, the foot pinion 1210 includes one or more fixing points 1212 (e.g., rails) for adjusting the position of the presser foot device 1100, for example, for adjusting the position of the groove 1130 relative to the aperture 1211 of the foot pinion. For example, another embodiment of the presser foot device 1100 is an integral part, for example, formed by a single milled or molded part, which includes features of the presser foot device 1100 and the presser foot pinion 1210, for example, formed as a presser foot device, which includes a plurality of pinion teeth forming a pinion, the axis of which is included in the mid-plane 1130MP of the groove.

[0077] For example, the device includes a caster pulley 1220, the axis of which is included in the mid-plane 1330MP of the groove. For example, the caster pulley 1220 includes an orifice 1221 on its rotation axis, for example for the passage of the fiber tow 100. For example, the caster pulley 1220 includes one or more fixing points 1222 (e.g., rails) for adjusting the position of the presser foot device 1100, for example, for adjusting the position of the groove 1130 relative to the orifice 1221 of the caster pulley. For example, another embodiment of the presser foot device 1100 is an integral part, for example, formed by a single milled or molded part, which includes the features of the presser foot device 1100 and the presser pulley 1220, the axis of which is included in the mid-plane 1130MP of the groove.

[0078] For example, foot surface 1150 includes a first material within a first section 1151 closer to the front end relative to the front end, and a second material within a second section 1152 further from the front end, wherein the thermal conductivity of the second material is at most half that of the first material. One or more of the first and second materials include, for example, steel alloys, such as hardened steel, such as DIN 1.3505 steel, such as DIN 1.3343 steel; alloys, such as metal alloys, including one or more of the following: copper, aluminum, iron, nickel, tin, titanium, tungsten, vanadium, and zinc; ceramics, glass, and polymers. In some embodiments, the foot surface includes a coating, such as a coating including one or more of the following: a metal; a hardened metal; a metal oxide; a ceramic; or a polymer, such as polytetrafluoroethylene. For example, the foot surface has a Rockwell hardness of HRC 55 or higher.

[0079] Figure 1M is a perspective view of the presser foot device 1100 including the heat sink 1155, and Figure 1NFIG2 is a cross-sectional side view of a presser foot device 1100 including a heat sink 1155. For example, foot surface 1150 includes heat sink 1155. For example, heat sink 1155 includes a plurality of blades 1155B, for example, evenly spaced. For example, the blades are moved by an air source, such as one or more ducts 1155D directed toward blades 1155B. For example, foot surface 1150 includes heat sink 1155, which forms a second section surrounding first section 1151 adjacent to groove 1130.

[0080] For example, flared end 1120 includes a first flared end portion 1120-1 that is adjacent to groove 1130, elevated a distance 1115Z from foot surface 1150, and separated from a heat sink portion 1155 included in foot surface 1150 by a second section 1152, wherein second section 1152 forms a thermally insulating portion between first flared end portion 1120-1 and foot surface 1150. For example, the thermally insulating portion of second section 1152 includes a thermally insulating material, such as one or more of ceramic, glass, polymer, polymer foam, elastomer, and a laminate including foam. For example, second section 1152 limits the thermal conductivity from first flared end portion 1120-1 to heat sink portion 1155 to less than 500 W / m 2 For example, the second section 1152 includes a structure including a plurality of ribs, such as including cutouts, that mechanically connect the first flared end portion 1120 - 1 to the heat sink portion 1155 .

[0081] Figure 1J 1 is a bottom view of a presser foot device 1100 including a groove, wherein the cross section of the groove includes one or more pairs of symmetrically opposed circular profile segments. For example, the cross section of the groove includes one or more pairs of symmetrically opposed circular profile segments 1130C11, 1130C12, 1130C21, 1130C22 relative to a midplane 1130MP, wherein the one or more pairs of symmetrically opposed circular profile segments 1130C11, 1130C12, 1130C21, 1130C22 are included at a groove depth greater than or equal to the groove depth of the radius 1130MR of the largest circular profile segment. For example, the cross-section of the groove includes a second pair of opposing circular contour segments 1130C21, 1130C22, which are located at a groove depth, for example along the groove midplane 1130MP, which is greater than the groove depth of the first pair of opposing circular contour segments 1130C11, 1130C12.

[0082] Figure 1K1 is a bottom view of a presser foot device 1100 including a groove having a cross-section comprising one or more U-shaped groove cross-sections that are scaled down into the groove. For example, the groove cross-section comprises one or more U-shaped groove cross-sections 1130U1, 1130U2 that are scaled down into the groove 1130, for example, along a groove midplane 1130MP. For example, an embodiment of the U-shaped groove 1130 comprises a semicircular portion joining each side of the U. Other embodiments comprise, for example, one or more of an elliptical, parabolic, and circular portion joining each side of the U.

[0083] Figure 1L 1 is a bottom view of a presser foot device 1100 including a groove having a cross-section comprising two or more straight edges joined by rounded corners. For example, groove 1130 includes a cross-section comprising two or more straight edges 1130S1, 1130S2 joined by rounded corners 1130F. For example, the two or more straight edges 1130S1, 1130S2 are symmetrically arranged relative to groove midplane 1130MP. For example, one embodiment of the groove cross-section forms a semi-rectangular shape with rounded corners.

[0084] For example, the distance between the first lip 1141 of the groove and the second lip 1142 of the groove is comprised in the range of 0.2 mm to 2 mm, for example comprised in the range of 0.2 mm to 1 mm.

[0085] For example, the width of the tow 100 (which includes, for example, a lip-to-lip distance 1130W between a first lip 1141 of the groove and a second lip 1142 of the groove, which is approximately equal to the width of the tow 100 ( Figure 6E ) in a groove 1130 having a width 100W (e.g., a margin of 2% to 20% greater than the width of the tow 100, e.g., 5% to 15% greater)) provides a method for constraining and guiding the orientation of the tow 100 based on the orientation of the mid-plane 1130MP of the groove and (by extension) the orientation of the straight leg section 1110. For example, the lip-to-lip distance 1130W is greater than the width 100W of the tow 100 by a margin within the range of 2% to 500%, e.g., 2% to 300%, e.g., 5% to 150%. For example, a tow 100 having a width 100W of approximately 0.4 mm is conveyed in a groove 1130 having a lip-to-lip distance 1130W within the range of 0.5 mm to 2 mm, e.g., 1 mm. For example, the width 100W of the tow 100 is determined by the tow forming assembly 3000 ( Figure 6A ) of the sheave 3531B( Figure 6D) is formed and defined by the width 3531BW of the groove 3531BG. For another exemplary embodiment, a tow 100 having a width 100W of about 0.8 mm is fed in the groove 1130, which has a lip-to-lip distance 1130W in the range of 1 mm to 2 mm (e.g., 1 mm).

[0086] For example, a method of rotating the presser foot device 1100 about the Z axis also rotates the tow 100 about the Z axis. For example, the method 5000, device, or system 2000 of rotating the tow 100 while the tow 100 translates relative to the object 200 provides a method of increasing the adhesion surface of the tow 100 on the object surface 200 and increasing the adhesion between the tow 100 and the object surface compared to an unrotated tow. For example, the method 5000 for applying an elongated fiber tow ( Figure 12 ) includes rotating 5310 the presser foot device 1100, for example, so that the rotation angle is tangent to the path of the presser foot device 1100 7001PT ( Figure 14 ) matching. For example, the method 5000, which includes rotating the tow 100 while applying the tow 100 to the curved path 7001-2 on the object surface 200, reduces the likelihood that the tow will separate from the object surface 200 and shortcut the tow's intended path. For example, the method 5000 of rotating the tow 100 within a groove 1300 that is substantially the same width as the tow 100 prevents a loss of tow positioning accuracy, such as that caused by unintended lateral position jumps of the tow, such as observed in systems that feed and translate tows or filaments within a channel that is significantly larger than the width of the tow 100.

[0087] Figure 2A is a perspective view of a system 2000 for applying elongated fiber tows, the system 2000 including a pinion-driven presser foot assembly 1100 , a foot shaft housing 2100 (which includes one or more heat sources 2110 ), and a heat exchanger housing 2200 . Figure 4AA cross-section of a system 2000 for applying an elongated fiber tow 100 to a surface 200 is presented, the system including a presser foot device 1100. For example, the presser foot device 1100 includes: a foot surface 1150 for pressing the fiber tow 100 onto the surface 200, the foot surface 1150 including a straight foot section 1110 for pressing the fiber tow 100 onto the surface 200, the straight foot section 1110 including a rear end 1112 and a front end 1111, the rear end 1112 and the front end 1111 defining a front direction Fx from the rear end to the front end; and a groove 1130 including a left lip 1141 and a right lip 1142 for guiding the tow to the foot surface 1150, the groove 1130 directing the tow to the foot surface 1150. The groove midplane 1130MP is defined as a planar portion of the groove along the centerline 1130ML between the left lip 1141 and the right lip 1142 of the groove 1130, the groove 1130 being engaged to the front end 1111 of the straight foot section 1110 and oriented at an elevation angle 1130A relative to the straight foot section 1110, wherein the groove 1130 includes a flared end 1120 engaged with the foot surface 1150; and a foot shaft housing 2100, characterized in that the foot shaft has a rotational axis Z defining a Z axis, wherein the rotational axis Z of the foot shaft is orthogonal to the straight foot section 1110 and is included in the groove midplane 1130MP.

[0088] For example, the presser foot device 1100 includes a hollow foot shaft 1200, the axis of which is colinear with the rotation axis Z of the foot shaft, and wherein a portion of the shaft forms a sliding fit within the foot shaft housing 2100. For example, the hollow foot shaft 1200 includes a through hole that is concentric with the outer diameter of the hollow foot shaft 1200. In some examples of the hollow foot shaft 1200, a portion of the shaft forms a rotational fit within the foot shaft housing 2100. For example, the foot shaft housing 2100 includes one or more heat sources 2110. The heat source 2110 includes, for example, one or more of the following: one or more resistive elements; and one or more inductive elements, for example, formed as one or more coils 2120, 2121, 2122, 2123.

[0089] For example, system 2000 includes a radiation source 2140 that includes infrared radiation directed toward groove 1130. For example, radiation source 2140 is located in a plane extending from the axis of rotation Z of the foot shaft to radiation source 2140, which is coplanar with groove midplane 1130MP. For example, radiation source 2140 includes one or more resistive elements, such as one or more rods, oriented in a direction coplanar with the axis of rotation Z of the foot shaft. For example, radiation source 2140 includes a radiation reflector, such as one or more oriented to reflect radiation toward one or more of groove 1130, flared end 1120, and object surface 200. For example, radiation source 2140 includes one or more optical fibers, such as one or more optical fibers, to direct radiation emitted by one or more lasers toward one or more of groove 1130, flared end 1120, and object surface 200.

[0090] Figure 3A and Figure 3B 2 is a top view of a foot spindle housing 2100, which includes one or more induction coils 2120, 2121, 2122, and 2123 as heat sources for the underlying presser foot device 1100. For example, the foot spindle housing 2100 includes one or more induction heating coils 2120, 2121, 2122, and 2123. For example, the axis of one or more of the induction heating coils 2120, 2121, 2122, and 2123 is parallel to the rotational axis Z of the foot spindle.

[0091] For example, the system includes temperature sensors 1170, 2170, 2270, which are included in one or more of: the foot shaft housing 2100; and the pressure foot device 1100. In some embodiments of the system 2000, the temperature sensor 2270 is included in the heat exchanger housing 2200. For example, the foot shaft housing 2100 includes a cylindrical sleeve 2130 coaxial with the rotational axis Z of the foot shaft.

[0092] For example, system 2000 includes one or more puck assemblies 2500 .

[0093] Figure 4B is a top view of rollers of a pinch roller assembly 2500 included in a system for applying an elongated fiber tow 100. For example, one or more of the pinch roller assembly 2500 includes a first roller 2510-1 and a second roller 2510-2, wherein a common tangent line to the first roller and the second roller is collinear with the rotational axis Z of the foot shaft. For example, in some embodiments, the common tangent line to the first roller and the second roller intersects the rotational axis Z of the foot shaft.

[0094] For example, one or more of the roller assemblies 2500 include a first roller 2510-1 and a second roller 2510-2, wherein one or more of the rollers 2510-1, 2510-2 include a rectangular groove 2510G located in the periphery of the roller. For example, a cross-section of the groove intersects the rotation axis Z of the foot shaft. For example, one or more of the first roller 2510-1 and the second roller 2510-2 can be rotated by, for example, a user acting on the roller support handle 2510H (e.g., Figure 5 2510H and is separated from another roller or brought back to another roller. For example, one or more rotation axes of the rollers are supported by roller support handles 2510H.

[0095] For example, system 2000 includes: an entry port 2415, which includes, for example, an internal cylindrical geometry for receiving a tube and one or more of a funnel for guiding a filament (e.g., a spun yarn or a tow), which includes, for example, one or more folds along a longitudinal axis (e.g., a Z-axis); and a tubular conduit 2417, which is used, for example, to straighten the filament and guide the filament from the entry port 2415 into the groove 2510G.

[0096] For example, system 2000 includes a tow cutter assembly 2300 including an orifice 2350 and a blade 2340, the orifice 2350 intersecting the rotational axis Z of the foot shaft. For example, an embodiment of the tow cutter assembly 2300 includes an ultrasonic cutter, such as a blade actuated at one or more ultrasonic frequencies.

[0097] For example, system 2000 includes a tow cutter assembly 2300 including a blade 2340 guided by a track 2330, the blade 2340 being mechanically coupled to a rotatable ring 2320 having an axis of rotation that is co-linear with the axis of rotation Z of the foot shaft. The rotatable ring is coupled to a drive assembly 2310 that includes, for example, one or more of: a gear; a pulley; and a motor 2355, such as a stepper motor.

[0098] For example, the system 2000 includes a heat exchanger housing 2200 disposed between the foot spindle housing 2100 and one or more of the one or more pressure roller assemblies 2500, the heat exchanger housing 2200 including a first through-hole 2250 having an axis co-linear with the foot spindle's rotational axis Z. In some embodiments of the system 2000, a temperature sensor 2270 is included in the heat exchanger housing 2200. For example, the heat exchanger housing 2200 is disposed between the tow cutter assembly 2300 and the foot spindle housing 2100.

[0099] Figure 4Cis a top cross-section of a heat exchanger housing 2200 including one or more conduits 2210. For example, the heat exchanger housing 2200 includes one or more conduits 2210. For example, the one or more conduits 2210 include one or more conduit ports 2215, such as controllable valves or vanes, for adjusting the flow rate of a fluid flowing inside the one or more conduits 2210. For example, the heat exchanger housing 2200 includes a conduit 2210 that forms a turning path of at least 180° around the rotation axis Z of the foot shaft. For example, the conduit forms one or more semicircular loops around the rotation axis Z of the foot shaft. For example, the heat exchanger housing 2200 includes a second through hole 2252, the axis of which is parallel to the rotation axis Z of the foot shaft. For example, the heat exchanger housing 2200 includes a drive shaft 1360 coupled to the presser foot device 1100. For example, the drive shaft includes a pinion 1310 coupled to the presser foot pinion 1210. For another example, as Figure 2B As shown in FIG, the drive shaft includes a pulley 1320 coupled to the presser foot pulley 1220.

[0100] For example, the heat exchanger housing 2200 forms a thermally conductive contact 1370 with the drive shaft 1360, which is coupled to the presser foot device 1100, wherein the interface conductance of the contact is greater than 500 W / m 2 / K.

[0101] For example, heat exchanger housing 2200 includes a tow conduit 2400, wherein the tow conduit includes an inlet portion 2410 and an outlet portion 2420, and wherein the axis of symmetry of the outlet portion is included in groove midplane 1130MP.

[0102] For example, a portion of the tow conduit 2400 includes a converging tow conduit nozzle or funnel 2420, wherein an outlet port 2420-O of the converging tow conduit nozzle is oriented toward the groove 1130, and wherein an axis of symmetry of the outlet port 2420-O is included in the groove midplane 1130MP. For example, the tow conduit 2400 includes an outlet conduit 2430, for example, aligned with the rotational axis Z of the foot shaft, and the outlet conduit 2430, for example, has an inner diameter that is lower than the inner diameter of the portion of the tow conduit 2400 included between the rollers 2510-1, 2510-2 and the tow conduit nozzle or funnel 2420. For example, the system 2000 includes a conduit extension 2440, the axis of which is aligned with the rotational axis Z of the presser foot device. For example, the conduit extension is aligned with the tow conduit 2400. In some embodiments, the conduit extension passes through one or more of: the through hole 2250 , the foot shaft housing 2100 ; and a portion of the presser foot device 1100 , such as a portion of the presser foot device that passes through the foot shaft housing 2100 .

[0103] For example, the system 2000 includes one or more ranging detector assemblies 2600, each of which includes a rangefinder 2650, one or more of which has a measuring axis ZR oriented in a direction parallel to the direction of the rotation axis Z of the foot shaft, wherein the distance 2630 from the measuring axis ZR of the ranging detector to the rotation axis Z of the foot shaft is greater than the distance 1115 from the rotation axis Z of the foot shaft to the rear end 1112 of the straight foot section and is less than 20 cm.

[0104] For example, one or more of the one or more ranging detector assemblies 2600 include a translation stage 2610. For example, the translation stage 2610 provides a method for adjusting the position of the one or more ranging detector assemblies 2600 relative to the presser foot device 1100.

[0105] For example, system 2000 includes a tow forming assembly 3000, for example, supported by a tow forming assembly chassis 3100. For example, tow forming assembly chassis 3100 includes one or more of: a ribbon orienter and tensioner assembly 3510; a ribbon preheating assembly 3520; a ribbon heater 3543; a tow forming assembly 3530; and a tow heating assembly 3540. For example, tow forming assembly 3000 includes one or more grooved pulleys 3522, 3531A, 3531B, wherein at least a portion of the groove is rectangular in cross-section. For example, tow forming assembly 3000 includes, for example, a ribbon orienter and tensioner assembly 3510 configured to apply a load to ribbon 90, for example, via a counterweight, a spring, or a servo motor, such as including a pulley 3511, such as including a flat-bottomed groove. For example, tow forming assembly 3000 includes ribbon preheating assembly 3520. For example, the ribbon preheat assembly 3520 includes one or more of the following: a first sheave 3522 including, for example, a flat-bottomed groove 3522G; and a wheel cooler 3522C. The wheel cooler includes, for example, one or more of the following: a blower including, for example, an air source and one or more orifices, such as located in the chassis 3100 of the tow forming assembly; and a cooling bath including, for example, water.

[0106] For example, tow forming assembly 3000 includes a belt post-heating assembly or first tow forming assembly 3530. For example, the cross-section of the groove of one or more second sheaves 3531A, 3531B includes a V-shaped groove entrance 3531E and a rectangular groove depth 3531D. For example, belt 90 is folded into tow 100 at second sheave 3531A. For example, first tow forming assembly 3530 includes a wheel cooler 3522C.

[0107] For example, system 2000 includes one or more infrared radiation sources 3542, 3543 directed into the path of tow 100. For example, tow heating infrared radiation source 3543 is included between first sheave 3522 and second sheave 3531A. For example, tow heating assembly 3540 (which, for example, includes tow heating infrared radiation source 3542) is included downstream of the tow from one or more of second sheaves 3531A, 3531B, such as at tow heating assembly 3540 of tow forming assembly 3000. For example, tow heating infrared radiation source 3542 includes an aperture 3542A for one or more of: inserting the tow; enabling visual monitoring of the tow; and heating only a portion of the periphery of the tow.

[0108] For example, system 2000 includes a tow puller assembly 3500. For example, the tow puller assembly is located downstream of the tow on the chassis 3100 of the tow forming assembly. For example, the tow puller assembly 3500 includes one or more pistol assemblies 3501, 3502, 3503, for example, three pistol assemblies. For example, one or more pistol assemblies 3501, 3502, 3503 are driven by a tow puller assembly motor 3550. For example, the tow puller assembly 3500 includes one or more of the following: a speed sensor, for example, for measuring or estimating tow speed, such as one or more of a wheel encoder or resolver mounted on one or more of the pistols and an optical sensor, for example, for monitoring the tow; a tension sensor, for example, mounted on one or more of the pistols; and a motor power sensor, for example, for estimating tension in the tow.

[0109] For example, system 2000 includes a tow buffer assembly 3600. For example, tow buffer assembly 3600 includes one or more flexible tube assemblies, the flexible tube assembly including a first tube 3610 and a second tube 3620, wherein the outer diameter of the first tube is smaller than the inner diameter of the second tube, and wherein the first tube is slidably inserted into the second tube. For example, buffer assembly 3600, wherein the outer diameter of the first tube is smaller than the inner diameter of the second tube, implements a method in which the first and second tubes slide relative to each other, for example, telescopically, as the tension on the tow 100 passing through the first and second tubes 3610, 3620 continuously increases and decreases as the tow 100 is supplied by the tow forming assembly 3000 and required by the pinch roller assembly 2500. For example, the first and second tubes 3610, 3620 telescopically slide into each other and form a loop 3655. For example, the tow inlet of the first tube 3610 is anchored by a first fastener 3610F. For example, the tow outlet of the second tube 3620 is anchored by a second fastener 3620F. For example, one or more of the first tube 3610 and the second tube 3620 are constrained by a one-way restrictor 3650 to allow the tubes 3610 and 3620 to move in a single direction (e.g., the radial direction of the loop). For example, the one-way restrictor 3650 includes one or more restrictor rollers 3651, such as two restrictor rollers 3651. For example, the restrictor rollers 3651 are slidably mounted on a track 3652, for example, oriented in the radial direction of the loop (e.g., a direction orthogonal to the direction in which the tow leaves the tow forming assembly 3000, such as a vertical direction). For example, one or more of the restrictor rollers 3651 are spring-loaded along the track direction. In some embodiments, the one-way restrictor 3650 includes a sensor (e.g., a position sensor, such as a strain gauge) to detect one or more of the tension and geometry of the loop.

[0110] For example, system 2000 includes a tow longitudinal tension detector 2710. For example, tension detector 2710 includes one or more wheels, such as one or more sliders, configured to contact tow 100 at a first end and coupled to a force measurement sensor, such as a strain gauge, at a second end.

[0111] For example, the system 2000 includes a slider 2800 including one or more axes 2810, 2820. For example, the slider 2800 includes a first axis 2810 that is orthogonal to a second axis 2820. For example, one or more of the one or more axes 2810, 2820 intersects a Z-direction extending groove midplane 1130MPZ that extends the groove midplane 1130MP in the Z direction.

[0112] For example, one or more of the one or more axes 2810, 2820 include two orthogonal axes 2810, 2820, the intersection of which is approximately located in the Z-direction extending groove midplane 1130MPZ of the Z-direction extending groove midplane 1130MP. For example, the intersection is included within a radius of the Z axis that is equal to three times the diameter of the largest diameter axis.

[0113] For example, the system 2000 includes a support chassis including a tubular clamp 2620 having an axis parallel to the rotational axis Z of the foot shaft.

[0114] For example, the system 2000 includes one or more of a press wheel motor 2550 coupled to the one or more press wheel assemblies 2500 , a tow cutter motor 2355 coupled to the tow cutter assembly 2300 , and a foot rotation motor 1350 coupled to the presser foot device 1100 .

[0115] For example, the system 2000 includes a dispenser nozzle outlet 2940 for dispensing a thermoplastic material onto the surface 200. For example, the dispenser nozzle outlet is suitable for dispensing a thermoplastic material comprising one or more of: a metal, such as metal powder; chopped fibers, such as chopped carbon fibers; a silicate, such as sand; a ceramic; a powder, such as carbon black powder; a silicone; a foam, such as urethane, polyurethane, or polystyrene foam; and an elastomer.

[0116] For example, the system 2000 includes a dispenser nozzle assembly 2900. The dispenser nozzle assembly 2900 includes, for example, an inlet 2915 including, for example, an internal cylindrical geometry for receiving a tube and one or more of a funnel for guiding a filament (e.g., a filament of thermoplastic material); one or more rollers 2910-1, 2910-2 including, for example, grooves 2910G located in the periphery of the roller and driven by a roller motor 2950; a tubular conduit 2917 for, for example, straightening the filament of material and guiding it from the inlet 2915 into the grooves 2910G; and a conduit 2920 for, for example, guiding the filament of material to the nozzle 2940.

[0117] For example, the system 2000 includes a dispenser nozzle extension actuator 2930 to adjust the Z-axis position of the discharge opening 2940 of the dispenser nozzle.

[0118] For example, the Z-axis position of the discharge opening 2940 of the dispenser nozzle is offset from the Z-axis position of the straight leg segment 1110 by an offset 2980 comprised within the range from -4 mm to +4 mm.

[0119] Figure 9 3800 is a perspective view of a system 2000 for applying elongated fiber tows mounted on a robotic arm 3800. For example, the system 2000 includes a robotic support 3800 for applying elongated fiber tows at one or more spatial locations (X F 、Y F 、Z F ) and one or more spatial orientations ( θ F , ψ F ) configures one or more of the position and speed of the presser foot device 1100 on the robot. For example, the robot support includes one or more motors 3810, 3820, 3830, 3840, 3850 to actuate one or more joints for configuring the presser foot device, for example, placed at the end effector position of the robot, to a certain spatial position and orientation.

[0120] Figure 11 A block diagram of a computer system 4000 is presented. For example, system 2000 includes computer system 4000. For example, the computer system 4000 includes a digital processor 4110, a computer-readable non-volatile storage device or medium 4120, a user interface device 4130, a data bus 4150 connected to one or more sensors 4170, 2650, 2710, 2170, 2270 and actuators 4180, 1350, 2550, 2120, 2121, 2122, 2123, 2300, 2110, 3000 included in the system, a memory 4160, and one or more communication interface devices 4140 for transmitting data between the digital processor 4110, the computer-readable non-volatile storage device 4120, the data bus 4150, the user interface device 4130, and one or more external systems 4200 located outside the system, the one or more external systems 4200 including one or more of a processor, a storage device, a user interface, an actuator, and a sensor.

[0121] Figure 12A block diagram of a method 5000 (e.g., a computer-based method including computer-readable instructions stored in a non-transitory storage medium) for applying an elongated fiber tow 100 to a surface 200 of an object is presented, the method comprising: translating 5100 the elongated fiber tow 100 into a groove 1130 of a presser foot device 1100 to a foot surface 1150 of the presser foot device 1100, the groove 1130 including a left lip 1141, a right lip 1142, and defining a groove midplane 1130MP along a midline 1130ML of the groove and extending until the left lip 1141 of the groove 1130 is aligned with the groove midplane 1130MP. 141 and the right lip edge 1142; guiding the fiber bundle in the groove to the flared end 1120 of the groove; bending the fiber bundle around the flared end of the groove to the straight leg section 1110 included in the foot surface 1150 of the presser foot device 5230, wherein the straight leg section 1110 includes a rear end 1112 and a front end 1111, which define a front direction Fx from the rear end to the front end, and the groove 1130 is joined to the front end of the straight leg section 1110 and is oriented at an elevation angle 1130A relative to the straight leg section; and pressing 5240 the fiber bundle between the straight leg section and the surface 200 of the object.

[0122] For example, one or more of translating 5100, guiding 5200, bending 5230, and pressing 5240 includes heating 5210 the fiber tow 100. For example, pressing 5240 includes cooling 5250 the fiber tow 100. For example, a method of cooling the fiber tow 100 includes contacting the fiber tow 100, such as by pressing the fiber tow 100 with a distal portion (relative to the groove 1130) or the heat sink portion 1155 of the presser foot device 1100. For example, pressing 5250 includes a first step including heating 5210 the fiber tow 100 and a second step including cooling 5250 the fiber tow 100.

[0123] For example, the method 5000 includes adjusting the electrical power 5220 delivered to one or more heat sources 2110 , 2120 , 2121 , 2122 , 2123 , 2140 for heating the fiber tow 100 .

[0124] For example, the method 5000 includes rotating 5310 the presser foot device 1100 about a rotation axis Z that is orthogonal to the straight foot section 1110 and included in the groove midplane 1130MP. For example, the method 5000 includes translating 5320 the presser foot device 1100 .

[0125] Figure 147000 is a top view of an object 7000 including a tow layer 7100 including a plurality of fiber tow segments 101, 102, 103. For example, method 5000 includes one or more of translating 5320 and rotating 5310 a presser foot device 1100 along paths 7001, 7002, 7003 from a path start point 7001-S to a path end point 7001-E, wherein a straight leg segment 1110 is collinear with a tangent line 7001T of the path of the presser foot device 1100 and a point of tangency 7001PT with the path 7001 is included within a groove midplane 1130MP. For example, method 5000 includes simultaneous translation and rotation. A method for forming a spiral path 7300 includes forming one or more paths, such as a spirally arranged, continuously arranged path 7001, 7002, 7003. For example, method 5000 includes forming an interior region 7500 (also referred to as filler 7500) that fills an area or volume in, for example, multiple stacked rows or layers 7100, which interior region 7500 is included within one or more of the outer contours formed by paths 7001, 7002, 7003 of object 7000.

[0126] For example, the fiber tow 100 translates within the groove 1130 at a speed equal to the speed at which the point of tangency 7001PT with the path 7001 translates along the path.

[0127] For example, method 5000 includes forming cuts 5330 in fiber tow 100 at locations 7001-E where the radius of curvature of the path is one or more of less than 2 mm, less than 3 mm, and less than 5 mm. For example, the radius of curvature of the path is a path planned by one or more path instructions, such as a path generated by a computer-based path planning system. For example, the path is segmented at locations where the path plan includes a radius of curvature below a threshold, such as one or more of the following: less than 2 mm; less than 3 mm; and less than 5 mm.

[0128] For example, method 5000 includes actuating 5340 the tow cutter assembly 2300 at positions 7001-C, 7002-C, 7003-C along paths 7001, 7002, 7003, wherein positions 7001-C, 7002-C, 7003-C are located prior to the end point of the path by a path length 2341 equal to the length 2341 of the fiber tow from the blade 2340 of the tow cutter assembly to the front end 1111 of the straight leg segment 1110.

[0129] For example, the method 5000 includes unwinding 3545 the tow 100 , wherein the unwinding includes rotating 5310 the presser foot device 1100 .

[0130] For example, method 5000 includes forming 5350 a measurement of distance 205 between straight leg segment 1110 and object surface 200. For example, the distance corresponds to a height along the Z-axis.

[0131] For example, method 5000 includes adjusting 5360 distance 205 between straight leg segment 1110 and object surface 200. For example, adjusting distance 205 is a function of one or more measurements of the distance from object surface 200, e.g., obtained using one or more of ranging detector assemblies 2600. For example, method 5000 includes adjusting 5370 distance 206 between dispenser nozzle 2940 and object surface 200. For example, adjusting distance 206 is a function of one or more measurements of the distance from object surface 200, e.g., obtained using one or more of ranging detector assemblies 2600. For example, method 5000 includes adjusting 5380 a distance offset 2980 of dispenser nozzle 2940 relative to object surface 200, e.g., along the Z-axis, based on distance 205 between straight leg segment 1110 and object surface 200.

[0132] For example, the method 5000 includes translating 5100 the fiber tow 100 within the groove 1130 by a length 110 comprised within the range of 2 mm to 30 mm; and guiding the presser foot device 1100 onto the object surface 200 along the landing trajectory 8010 , 8020 , 8030 .

[0133] For example, method 5000 includes forming 5110 one or more folds along the length of fiber tow 100 by passing fiber band 90 through one or more grooves having a rectangular cross-section. For example, passing includes engaging fiber band 90 into and out of one or more grooves, such as static grooves, such as grooves of one or more sheaves. For example, passing results in one or more of: aligning band 90; compressing band 90; and folding band 90 into, for example, tow 100.

[0134] For example, forming 5110 one or more folds includes threading the fiber ribbon 90 within one or more grooves 3522G, 3531AG, 3531BG included on one or more sheaves 3522, 3531A, 3531B.

[0135] For example, the method 5000 includes obtaining 5120 a measurement of the longitudinal tension of the fiber tow 100 from the tow longitudinal tension detector 2710 .

[0136] For example, method 5000 includes adjusting 5130 a speed of translation 5100 of tow 100 based on a measurement of the longitudinal tension of fiber tow 100 from tow longitudinal tension detector 2710 .

[0137] Figure 13 A block diagram of instructions 6000 for a method included in a computer readable non-volatile storage device 4120 is presented. For example, the instructions 6000, or a portion thereof, represents a method, such as a computer-implemented method. For example, the computer readable non-volatile storage device 4120 includes executable instructions 6000 that, when executed by one or more processors 4110 of a system 2000 for applying an elongated fiber tow 100 to a surface 200 of an object, causes the system 2000 to at least: a) command 6100 one or more of a position and a speed of a first tow entraining motor 2550 such that the elongated fiber tow 100 translates along a groove 1130 of a presser foot assembly; and b) command 6310 one or more of a position and a speed of a second motor 1350 coupled to and rotating the presser foot assembly 1100, wherein the presser foot assembly 1100 includes The invention provides a foot surface 1150 for pressing a fiber bundle 100 onto a surface 200 of an object, wherein the foot surface 1150 includes a straight foot section 1110 for pressing the fiber bundle 100 onto the surface 200 of an object, wherein the straight foot section 1110 includes a rear end 1112 and a front end 1111, wherein the rear end 1112 and the front end 1111 define a front direction Fx from the rear end to the front end, and wherein the presser foot device 1100 rotates around a rotation axis Z, which is orthogonal to the straight foot section 1110 and is included in a groove midplane 1130MP along a center line 1130ML of the groove, wherein the center line 1130ML is included between a left lip edge 1141 and a right lip edge 1142 of the groove.

[0138] For example, the instructions 6000 include instructions for a method in which the speed at which the first motor 2550 is commanded 6315 is a function of the speed at which the second motor 1350 is commanded 6310 .

[0139] For example, the instructions 6000 also include instructions for a method of commanding 6315 a third motor 2355 coupled to the tow cutter assembly 2300 and causing the tow cutter assembly to move the blade 2340 from the first position to the second position. For example, the instructions 6000 include instructions for a method of commanding 6315 a third motor 2355 coupled to the tow cutter assembly 2300 and causing the tow cutter assembly to move the blade 2340 from the first position to the second position. Figure 14 ) at the curvature of the tow. For example, a cut may be commanded after reaching cutting positions 7001-C, 7002-C, or 7003-C to form a complete cut across the entire cross-section of the tow. For example, a cut may be commanded to form a partial cut across a portion of the cross-section of the tow. For example, the extent of the cut across the cross-section of the tow may be a function, such as a linear function, of the radius of curvature of the path, such as at the point of tangency 7001PT.

[0140] For example, instructions 6000 include instructions for a method for adjusting the speed 6345 of the first motor 2550 based on a command sent to the third motor 2355 .

[0141] For example, the instructions 6000 include instructions for a method for acquiring 6350 rangefinder measurement data from one or more range detector assemblies 2600 .

[0142] For example, instructions 6000 include instructions for a method for adjusting 6355 the speed of the first motor 2550 based on measurements obtained from one or more ranging detector assemblies 2600 .

[0143] For example, instructions 6000 include instructions for a method for acquiring 6120 measurement data from one or more tow longitudinal tension detectors 2710 .

[0144] For example, instructions 6000 include instructions for a method for adjusting 6130 the speed of first motor 2550 based on measurements taken from one or more of the one or more tow longitudinal tension detectors 2710 .

[0145] For example, the instructions 6000 include instructions for a method for adjusting 6135 the relative speeds of one or more first motors 2550 , 3550 based on measurements taken from one or more of the one or more tow longitudinal tension detectors 2710 .

[0146] For example, instructions 6000 include instructions for a method for adjusting 6220 the infrared radiation power of one or more of: one or more infrared radiation sources 3542, 3543, 2140; and one or more heat sources 2110, 2120, 2121, 2122, 2123. For example, instructions for adjusting 6220 the infrared radiation power include adjusting a power supply, such as in one or more of voltage, current, and duty cycle. For example, instructions 6000 include instructions for adjusting 6250 tow cooling. For example, one or more of the instructions to adjust 6220 infrared radiation power and the instructions to adjust 6250 bundle cooling include instructions to make adjustments based on one or more of: a bundle tension measurement; a low translation speed; a speed of one or more motors 2550, 3550, 2950; a speed of one or more wheels 3522, 3531; one or more bundle cross-sectional dimensions; one or more thermoplastic material cross-sectional dimensions; a rotational speed of one or more rollers 2510-1, 2510-2, 2910-1, 2910-2; a temperature measured by one or more temperature sensors 1170, 2170, 2270; a relative amount of thermoplastic material included in the bundle, such as in the bundle cross-section; and an ambient temperature measurement. For example, instructions to adjust 6250 bundle cooling include instructions to adjust one or more of the following, for example, by sending one or more commands to one or more flow control devices (e.g., valves or vanes) included in, for example, one or more ports 2215: the flow rate of a cooling fluid, such as the flow rate of a cooling fluid flowing within the heat exchanger housing 2200.

[0147] For example, instructions 6000 include instructions for storing 6400 one or more digital tool path instructions 7001-S, 7001-1, 7001-2, 7001-3, 7001-E, 7002-S, 7002-1, 7002-2, 7002-E, 7003-S, 7003-1 including one or more of the position and orientation of the presser foot device 1100.

[0148] For example, instructions 6000 include instructions for a method for inserting 6405 one or more commands for a third motor 2355 coupled to the tow cutter assembly 2300 into digital tool path instructions 7001-S, 7001-1, 7001-2, 7001-3, 7001-E, 7002-S, 7002-1, 7002-2, 7002-E, 7003-S, 7003-1 based on one or more of a path length and one or more path curvatures.

[0149] For example, instructions 6000 include instructions for a method of inserting 6405 one or more instructions to command unwinding 6406 tow 100 , including a command to actuate second motor 1350 .

[0150] Figure 10 6 is a top view of a system 2000 for applying an elongated fiber tow, including an XY stage 3900 that also includes a Z-actuated object support 3932. For example, the stage 3900 includes an X motor 3910 for translating one or more of the presser foot device 1100 and the system 2000 in the X direction and a Y motor 3920 for translating in the Y direction. For example, the stage 3900 includes a Z motor 3930 for actuating the object support 3932 in the Z direction. For example, the instructions 6000 include instructions for commanding 6320 one or more motors 3810, 3820, 3830, 3840, 3850, 3910, 3920, 3930 to move at one or more spatial locations at coordinates X. F 、Y F 、Z F and instructions for a method of configuring one or more of the position and velocity of the presser foot device 1100 at one or more spatial orientation coordinates.

[0151] For example, the instructions 6000 include instructions for configuring the position (X) of the presser foot assembly, such as by commanding one or more motors 3820, 3830, 3840, 3850, 3930, based on measurements obtained from one or more range detector assemblies 2600. F 、Y F 、Z F ; θ F , ψ F ) and velocity. For example, adjusting the distance 205 includes instructions for a method of adjusting 6360 the distance 205 between the right-angle segment 1110 and the object surface 200 based on one or more of: a velocity and a speed. For example, adjusting the distance 205 includes instructions, wherein the distance is a function of one or more measurements of the distance from the object surface 200 (e.g., data obtained from one or more of the ranging detector assemblies 2600).

[0152] For example, instructions 6000 include instructions 6360 for a method for adjusting distance 205 between straight leg segment 1110 and object surface 200 along rotation axis Z to a value within a range of 0.05 mm to 1.0 mm. For example, the value is within a range of 0.15 mm to 0.5 mm, such as 0.2 mm to 0.3 mm, and for example 0.25 mm.

[0153] For example, the instructions 6000 include instructions 6360 for a method of translating and rotating the presser foot device 1100 along paths 7001, 7002, 7003 from path start points 7001-S, 7002-S to path end points 7001-E, 7002-E, wherein the second motor 1350 is commanded so that the straight leg segment 1110 remains collinear with a local tangent line 7001T to the paths 7001, 7002, 7003 of the presser foot device 1100, and the tangent point 7001PT remains within a segment extending from the front end 1111 of the straight leg segment to the center line 1130ML of the groove. For example, the translation and rotation occur simultaneously.

[0154] For example, the instructions 6000 include instructions 6370 for a method for adjusting the distance 206 between the nozzle 2940 and the object surface 200. For example, the instructions 6370 for adjusting the distance 206 are a function of one or more of: the distance 206 between the nozzle 2940 and the object surface 200; an offset of the nozzle 2940 relative to the presser foot assembly 1100, for example, along one or more of the X-axis, the Y-axis, and the Z-axis, such as where the Z-axis passes through the axis of rotation of the presser foot assembly; a three-dimensional geometric feature of the object surface; a velocity of one or more of the presser foot assembly 1100 and the nozzle 2940 relative to the object surface 200; and a three-dimensional geometric feature of the paths 7001, 7002, 7003, such as a curvature of the path including a curved portion between two straight portions in one or more of the X, Y, and Z dimensions, such as at a tangent point 7001PT at a point of maximum curvature of the curved portion. For example, forming a path including a portion comprising one or more curves or bends includes reducing the distance 206 between the nozzle 2940 and the object surface 200 within the curved portion compared to the distance 206 in a straight portion, for example according to a rule such as a linear function including the velocity.

[0155] For example, the instructions 6000 include instructions 6380 for a method for adjusting a distance offset, e.g., along one or more of the X-axis, the Y-axis, and the Z-axis, between the presser foot assembly 1100 and the nozzle 2940. For example, the instructions 6380 for adjusting the distance offset are a function of the three-dimensional geometric features of the paths 7001, 7002, and 7003, e.g., to follow height changes in the paths, e.g., to maintain a constant height of the nozzle 2940 relative to the object surface 200.

[0156] For example, instructions 6000 include instructions 6390 for a method of guiding a presser foot device 1100 onto an object surface 200 along landing trajectories 8010, 8020. The landing trajectory includes, for example, a trajectory portion 8030 parallel to the object surface 200 at a distance or height 205 relative to the object surface 200 (equal to the thickness 215 of the pressed filament or folded tow), such as in the range of about 30 μm to about 3 mm, such as about 50 μm to about 1 mm, or about 100 μm to about 400 μm. For example, the landing trajectory reaches a certain distance or height relative to the object surface 200 before the rotation axis Z of the foot shaft is positioned on the object surface 200. For example, the landing trajectory includes a flattened portion 8020 to blend, for example, a descending trajectory 8010 toward the object surface (e.g., a straight descending trajectory) with a trajectory portion parallel to the object surface. For example, a tangent to the descent trajectory 8010 (e.g., before the flattening portion 8020) forms an angle relative to the object surface 200 that is included in the range of 0° to 90° (e.g., 3° ​​to 60°, such as 3° to 45°). For example, the landing trajectory is commanded by a rangefinder 2650 positioned before the presser foot device 1100. For example, the landing trajectory starts from an initial approach height 216 relative to the object surface, which initial approach height 216 is included in the range of 100 mm to 30 μm, such as 50 mm to 30 μm. For example, the instructions 6390 for guiding the presser foot device along the landing trajectory include instructions for deploying an initial tow length 110, such as for anchoring the tow to a surface beyond the foot surface 1150 of the presser foot device. For example, the initial tow length 110 has a range from 0.5 mm to 50 mm, such as from 1 mm to 30 mm, such as from 2 mm to 25 mm, such as from 10 mm to 20 mm.

[0157] For example, the instructions 6000 include commands for one or more motors 3810, 3820, 3830, 3840, 3850, 3910, 3920, 3930, 2930 to move at one or more spatial position coordinates (X F 、Y F 、Z F ) and one or more spatial orientation coordinates ( θ F , ψ F ) configures one or more of the position and velocity of the dispenser nozzle 2940 at instruction 6420.

[0158] For example, the instructions 6000 include instructions 6430 for instructing the dispenser nozzle extension actuator 2930 to adjust one or more of the position 2980 and speed of the dispenser nozzle based on one or more of the position 205 and speed of the presser foot assembly 1100. For example, the instructions 6000 (e.g., instructions 6430) include instructions for adjusting the speed of one or more entrainment motors (e.g., the dispenser nozzle entrainment motor 2950), for example, to entrain thermoplastic material. For example, the speed is adjusted based on one or more of: the speed of the tow entrainment motor; the curvature of the curved portion of the path; and the distance 206 between the nozzle 2940 and the object surface 200.

[0159] While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the present invention may be devised without departing from the basic scope thereof. The scope of the present disclosure, therefore, is to be determined by the claims that follow.

[0160] In the context of describing the disclosed embodiments (especially in the context of the following claims), the use of the terms "a" and "an" and "the" and similar indicators should be interpreted as covering the singular and plural, unless otherwise stated in this article or clearly contradicted by the context. Unless otherwise stated, the terms "include", "have", "cover" and "include" should be interpreted as open terms (i.e., meaning "including, but not limited to,"). The term "connected" should be interpreted as partially or completely included, attached to or joined together, even if there are intermediary things. Unless otherwise stated herein, the description of the numerical range herein is only intended to be used as a shorthand method for individually referring to each individual numerical value falling within the range, and each individual numerical value is incorporated into the specification as if it were individually stated in this article. Unless otherwise stated herein or clearly contradicted by the context, all methods described herein can be performed in any appropriate order. Unless otherwise stated, the use of any and all examples or exemplary language (e.g., "such as") provided herein is only intended to better illustrate the embodiments of the present invention, rather than to limit the scope of the present invention. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0161] Preferred embodiments of the present disclosure are described herein, including the best mode known to the inventors for carrying out the invention. Variations of these preferred embodiments may become apparent, for example, upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend that the invention be practiced otherwise than as specifically described herein.

[0162] Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed unless otherwise indicated herein or clearly contradicted by context.

[0163] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

Claims

1. A presser foot device (1100) for applying an elongated fiber bundle (100) to a surface (200) of an object, the presser foot device comprising: Foot surface (1150), The foot surface (1150) is used to press the elongated fiber bundle (100) onto the object surface (200), The foot surface (1150) includes a straight foot section (1110) for pressing the elongated fiber tow (100) onto the object surface (200), The straight leg section (1110) includes a rear end (1112) and a front end (1111), wherein the rear end (1112) and the front end (1111) define a front direction (Fx) from the rear end to the front end; a groove (1130), the groove (1130) including a left lip edge (1141) and a right lip edge (1142), The groove (1130) is used to guide the elongated fiber bundle to the foot surface (1150), The groove (1130) defines a groove midplane (1130MP) as a planar portion along the groove midline (1130ML) and extending between the left lip (1141) and the right lip (1142) of the groove (1130), The groove (1130) is engaged to the front end (1111) of the straight leg section (1110) and is oriented at an elevation angle (1130A) relative to the straight leg section (1110), The groove (1130) includes a flared end (1120) that joins the groove to the front end of the straight leg section on the foot surface (1150); as well as Hollow foot shaft (1200), in A portion of the hollow axle has an outer diameter and an axis of rotation (Z) and is configured to form a rotational fit within the axle housing (2100), and The rotation axis is orthogonal to the straight leg section (1110) and is included in the groove mid-plane.

2. The device of claim 1, wherein the elevation angle (1130A) of a portion of the groove (1130) is 90°.

3. The device of claim 1, wherein the groove (1130) includes a flared inlet (1133) located at a groove inlet (1130E), the groove inlet (1130E) being located at an end opposite to the end of the flared end (1120).

4. The apparatus of claim 1 , wherein the foot surface ( 1150 ) comprises: a first toe surface (1161) located at a first side of a mid-plane (1130MP) of the groove and oriented at a first elevation angle (1161A1) and a first azimuth angle (1161A2) away from the frontal direction (Fx); as well as a second toe surface (1162) located at a second side of the mid-plane (1130MP) of the groove and oriented at a second elevation angle (1162A1) and a second azimuth angle (1162A2) away from the frontal direction (Fx), Wherein the first azimuth angle (1161A2) and the second azimuth angle (1162A2) are included in the range of 30° to 90° relative to the front direction (Fx).

5. The apparatus of claim 4, wherein the first azimuth angle (1161A2) and the second azimuth angle (1162A2) are approximately 90° relative to the front direction (Fx).

6. The apparatus of claim 4, wherein the first toe surface (1161) and the second toe surface (1162) are coplanar.

7. The device of claim 1, wherein the flared end (1120) comprises a chamfer (1125), the chamfer (1125) having an elevation angle (1125A) in the range of 30° to 70° relative to the front direction (Fx).

8. The device of claim 1, wherein the flared end (1120) includes a radius (1120F) joining the groove (1130) to the straight leg section (1110).

9. The apparatus of claim 1, wherein the foot surface (1150) is planar.

10. An apparatus as claimed in claim 1, wherein, viewed from a cross-section of a YZ plane orthogonal to the straight leg segment (1110), the foot surface (1150) includes one or more elevated profile portions (1171, 1172) facing the object surface (200), and the one or more elevated profile portions (1171, 1172) are elevated away from the object surface (200) in the Z direction relative to the straight leg segment (1110).

11. The device of claim 10, wherein one or more of the one or more elevated profile portions (1171, 1172) form an elevated curve (1171C, 1172C).

12. The device of claim 10, wherein one or more of the one or more elevated contour portions (1171, 1172) form an elevated straight line (1171L, 1172L).

13. A device as claimed in claim 1, wherein the foot surface (1150) includes an orientation segment (1150A) of a truncated hollow body of revolution, the axis of the truncated hollow body of revolution being included in the mid-plane (1130MP) of the groove, wherein the orientation segment (1150A) is included in the range of 180° to 320°.

14. The device of claim 1, wherein the device comprises a foot pinion (1210), the axis of the foot pinion (1210) being included in the mid-plane (1130MP) of the groove.

15. The device of claim 1, wherein the device comprises a caster (1220), the axis of the caster (1220) being included in the mid-plane (1130MP) of the groove.

16. A device as claimed in claim 1, wherein the foot surface (1150) includes a first material in a first section (1151) close to the front end relative to the front end and a second material in a second section (1152) away from the front end, wherein the thermal conductivity of the second material is at most half of the thermal conductivity of the first material.

17. The apparatus of claim 1, wherein the foot surface (1150) includes a heat sink (1155).

18. The apparatus of claim 1, wherein the foot surface (1150) includes a heat sink (1155) forming a surrounding second section around a first section (1151) proximate the groove (1130).

19. The device of claim 1, wherein the flared end (1120) includes a first flared end portion (1120-1), the first flared end portion (1120-1) being adjacent to the groove (1130), elevated a distance (1115Z) from the foot surface (1150) and separated from a heat sink portion included in the foot surface (1150) by a second section (1152), and wherein the second section (1152) forms a thermal insulation portion between the first flared end portion (1120-1) and the foot surface (1150).

20. A device as described in claim 1, wherein the cross-section of the groove includes one or more pairs of symmetrically opposite circular contour segments (1130C11, 1130C12, 1130C21, 1130C22) relative to the mid-plane (1130MP), and the one or more pairs of symmetrically opposite circular contour segments (1130C11, 1130C12, 1130C21, 1130C22) are included at a groove depth greater than or equal to the radius (1130MR) of the largest circular contour segment.

21. The device of claim 1, wherein the cross-section of the groove (1130) comprises one or more U-shaped groove cross-sections (1130U1, 1130U2) scaled down into the groove (1130).

22. The device of claim 1, wherein the groove (1130) comprises a cross-section comprising two or more straight sides (1130S1, 1130S2) joined by rounded corners (1130F).

23. The device of claim 1, wherein the distance between the left lip (1141) of the groove and the right lip (1142) of the groove is comprised in the range of 0.2 mm to 2 mm.

24. A system (2000) for applying an elongated fiber tow (100) to a surface (200), the system comprising: A presser foot device (1100), the presser foot device (1100) comprising: Foot surface (1150), The foot surface (1150) is used to press the elongated fiber bundle (100) onto the object surface (200), The foot surface (1150) includes a straight foot section (1110) for pressing the elongated fiber tow (100) onto the object surface (200), The straight leg section (1110) includes a rear end (1112) and a front end (1111), wherein the rear end (1112) and the front end (1111) define a front direction (Fx) from the rear end to the front end; a groove (1130), the groove (1130) including a left lip edge (1141) and a right lip edge (1142), The groove (1130) is used to guide the elongated fiber bundle to the foot surface (1150), The groove (1130) defines a groove midplane (1130MP) as a planar portion along a midline (1130ML) of the groove between the left lip (1141) and the right lip (1142) of the groove (1130), The groove (1130) is engaged to the front end (1111) of the straight leg section (1110) and is oriented at an elevation angle (1130A) relative to the straight leg section (1110), wherein the groove (1130) includes a flared end (1120) that joins the groove to the front end of the straight leg section on the foot surface (1150), wherein the presser foot device includes a hollow foot shaft (1200) for translating the elongated fiber tow to the groove, the axis of the hollow foot shaft being located in the groove mid-plane; and A portion of the hollow foot shaft has an outer diameter and a rotation axis (Z) and is configured to form a rotational fit within the foot shaft housing (2100), the rotation axis (Z) of the hollow foot shaft being orthogonal to the straight foot section (1110) and included in the groove midplane (1130MP).

25. The system of claim 24, wherein the foot shaft housing (2100) includes one or more heat sources (2110).

26. The system of claim 24, further comprising a radiation source (2140), the radiation source (2140) comprising infrared radiation directed toward the groove (1130).

27. The system of claim 24, wherein the foot shaft housing (2100) comprises one or more induction heating coils (2120, 2121, 2122, 2123).

28. The system of claim 27, wherein the axis of one or more of the induction heating coils (2120, 2121, 2122, 2123) is parallel to the axis of the rotation axis (Z) of the hollow foot shaft.

29. The system of claim 24, further comprising a temperature sensor (1170, 2170, 2270), the temperature sensor (1170, 2170, 2270) being included in one or more of: the foot shaft housing (2100); and the presser foot device (1100).

30. The system of claim 24, wherein the foot shaft housing (2100) includes a cylindrical sleeve (2130) coaxial with the axis of rotation (Z) of the hollow foot shaft.

31. The system of claim 24, further comprising one or more pinch wheel assemblies (2500).

32. A system as described in claim 31, wherein one or more of the pressure roller assemblies (2500) include a first roller (2510-1) and a second roller (2510-2), wherein a common tangent to the first roller and the second roller is colinear with the rotation axis (Z) of the hollow foot shaft.

33. A system as described in claim 31, wherein one or more of the pressure roller assemblies (2500) include a first roller (2510-1) and a second roller (2510-2), wherein one or more of the first roller (2510-1) and the second roller (2510-2) include a rectangular groove (2510G) located in the periphery of one or more of the first roller and the second roller.

34. A system as described in claim 31, wherein one or more of the pressure wheel assemblies (2500) include a first roller (2510-1) and a second roller (2510-2), wherein one or more of the first roller (2510-1) and the second roller (2510-2) include a rectangular groove (2510G) located in the periphery of one or more of the first roller and the second roller, and wherein a cross-section of the rectangular groove located in the periphery of one or more of the first roller and the second roller intersects with the rotation axis (Z) of the hollow foot shaft.

35. The system of claim 24, further comprising a tow cutter assembly (2300), the tow cutter assembly (2300) comprising an orifice (2350) and a blade (2340), the orifice (2350) intersecting the axis of rotation (Z) of the hollow foot shaft.

36. The system of claim 24, further comprising a tow cutter assembly (2300), the tow cutter assembly comprising a blade (2340) guided by a track (2330), the blade (2340) being mechanically coupled to a rotatable ring (2320), the axis of rotation of the rotatable ring (2320) being colinear with the axis of rotation (Z) of the hollow foot shaft.

37. The system of claim 31 , further comprising a heat exchanger housing (2200) disposed between the foot shaft housing (2100) and one or more of the one or more pressure wheel assemblies (2500), the heat exchanger housing (2200) comprising a first through hole (2250), the axis of the first through hole (2250) being collinear with the axis of rotation (Z) of the hollow foot shaft.

38. The system of claim 37, wherein the heat exchanger housing (2200) is disposed between a tow cutter assembly (2300) and the foot shaft housing (2100).

39. The system of claim 37, wherein the heat exchanger housing (2200) comprises one or more conduits (2210).

40. The system of claim 37, wherein the heat exchanger housing (2200) includes a conduit (2210) that forms a turning path of at least 180° around the axis of rotation (Z) of the hollow foot shaft.

41. The system of claim 37, wherein the heat exchanger housing (2200) comprises a second through hole (2252), the axis of the second through hole (2252) being parallel to the rotation axis (Z) of the hollow foot shaft.

42. The system of claim 37, wherein the heat exchanger housing (2200) includes a drive shaft (1360) coupled to the presser foot assembly (1100).

43. The system of claim 37, wherein the heat exchanger housing (2200) forms a thermally conductive contact (1370) with the drive shaft (1360), the drive shaft (1360) being coupled to the presser foot device (1100), wherein the interface conductance of the contact is greater than 500 W / m 2 / K.

44. The system of claim 24, further comprising a tow conduit (2400), wherein the tow conduit comprises an inlet portion (2410) and an outlet portion (2420), and wherein the axis of symmetry of the outlet portion is included in the groove midplane (1130MP).

45. A system as described in claim 44, wherein a portion of the filament bundle conduit (2400) includes a converging outlet portion (2420), the converging outlet (2420-O) of the filament bundle conduit is oriented toward the groove (1130), and wherein the symmetry axis of the outlet (2420-O) is included in the groove midplane (1130MP).

46. ​​The system of claim 24, further comprising one or more distance detector assemblies (2600), the distance detector assembly (2600) comprising a rangefinder (2650), one or more of the measurement axes (ZR) of the rangefinder being oriented in a direction parallel to the direction of the rotation axis (Z) of the hollow foot shaft, wherein a distance (2630) from the measurement axis (ZR) of the rangefinder to the rotation axis (Z) of the hollow foot shaft is greater than a distance (1115) from the rotation axis (Z) of the hollow foot shaft to the rear end (1112) of the straight foot section and is less than 20 cm.

47. The system of claim 46, wherein one or more of the one or more ranging detector assemblies (2600) comprises a translation stage (2610).

48. The system of claim 24, further comprising a tow forming assembly, the tow forming assembly (3000) comprising one or more sheaves (3522, 3531), wherein at least a portion of the cross-section of the grooves of the sheaves is rectangular.

49. The system of claim 48, wherein the cross-section of the groove of one or more sheaves (3531) comprises a V-shaped groove entry (3531E) and a rectangular groove depth (3531D).

50. The system of claim 48, further comprising one or more infrared radiation sources (3542, 3543) directed into the path of the elongated fiber tow (100).

51. The system of claim 24, further comprising a tow buffer assembly (3600).

52. A system as described in claim 51, wherein the filament bundle buffer assembly (3600) includes one or more flexible tube assemblies, the flexible tube assembly including a first tube (3610) and a second tube (3620), wherein the outer diameter of the first tube is smaller than the inner diameter of the second tube, and wherein the first tube is slidably inserted into the second tube.

53. The system of claim 24, further comprising a tow longitudinal tension detector (2710).

54. The system of claim 24, further comprising a sliding head (2800), the sliding head (2800) comprising one or more axes (2810, 2820).

55. The system of claim 54, wherein one or more of the one or more axes (2810, 2820) intersects a Z-direction extended groove midplane (1130MPZ), the Z-direction extended groove midplane extending the groove midplane (1130MP) in the Z direction.

56. A system as described in claim 54, comprising two orthogonal axes (2810, 2820), the intersection of which is approximately located on the Z-direction extended groove midplane (1130MPZ), and the Z-direction extended groove midplane extends the groove midplane (1130MP) in the Z direction.

57. The system of claim 24, further comprising a support chassis comprising a tubular clamp (2620), the axis of the tubular clamp (2620) being parallel to the axis of rotation (Z) of the hollow foot shaft.

58. The system of claim 24, further comprising one or more of a press wheel motor (2550) coupled to one or more press wheel assemblies (2500), a tow cutter motor (2355) coupled to a tow cutter assembly (2300), and a foot rotation motor (1350) coupled to the presser foot device (1100).

59. The system of claim 24, further comprising a dispenser nozzle outlet (2940) for dispensing thermoplastic material onto the surface (200) of the object.

60. The system of claim 59, further comprising a dispenser nozzle extension actuator (2930) to adjust the Z-axis position of a discharge opening (2940) of the dispenser nozzle.

61. A system as described in claim 59, wherein the Z-axis position of the discharge outlet (2940) of the dispenser nozzle deviates from the Z-axis position of the straight leg section (1110) by an offset (2980) included in the range from -4 mm to +4 mm.

62. The system of claim 24, further comprising a robotic support (3800) for positioning the robot at one or more spatial locations (X F 、Y F 、Z F ) and one or more spatial orientations of configuring one or more of the positions and speeds of the presser foot device (1100).

63. The system of claim 24, further comprising one or more of a digital processor (4110), a computer-readable non-volatile storage device (4120), a user interface device (4130), a data bus (4150) connected to one or more sensors (4170, 2650, 2710, 2170, 2270) and actuators (4180, 1350, 2550, 2120, 2121, 2122, 2123, 2300, 2110, 3000) included in the system, and a communication interface device (4140) for transferring data between the digital processor (4110), the computer-readable non-volatile storage device (4120), the data bus (4150), the user interface device (4130), and one or more external systems (4200) located outside the system, the one or more external systems (4200) comprising one or more of a processor, a storage device, a user interface, an actuator, and a sensor.

64. A method (5000) for applying an elongated fiber tow (100) to a surface (200), the method comprising: The elongated fiber bundle (100) entering the groove (1130) of the presser foot device (1100) is translated (5100) to the foot surface (1150) of the presser foot device (1100), The groove (1130) includes a left lip (1141) and a right lip (1142), and defines a groove midplane (1130MP) along a midline (1130ML) of the groove and extending between the left lip (1141) and the right lip (1142) of the groove (1130); guiding (5200) the elongated fiber bundle within the groove to the flared end (1120) of the groove; bending (5230) the elongated fiber bundle around the flared end of the groove to a straight foot section (1110) included in the foot surface (1150) of the presser foot device, The straight leg section (1110) includes a rear end (1112) and a front end (1111), wherein the rear end (1112) and the front end (1111) define a front direction (Fx) from the rear end to the front end, and The groove (1130) is joined to the front end of the straight leg section (1110) and is oriented at an elevation angle (1130A) relative to the straight leg section, and and wherein the presser foot device comprises a hollow foot shaft (1200), a portion of the hollow foot shaft having an outer diameter and a rotation axis (Z) and configured to form a rotational fit within the foot shaft housing (2100), the rotation axis being orthogonal to the straight foot section (1110) and included in the groove midplane, The elongated fiber bundle is compressed (5240) between the straight leg section and the object surface (200).

65. The method of claim 64, wherein one or more of translating (5100), guiding (5200), bending (5230), and pressing (5240) includes heating (5210) the elongated fiber tow (100).

66. The method of claim 64, wherein pressing (5240) includes cooling (5250) the elongated fiber tow (100).

67. A method as claimed in claim 64, wherein pressing (5240) includes a first step and a second step, wherein the first step includes heating (5210) the slender fiber bundle (100) and the second step includes cooling (5250) the slender fiber bundle (100).

68. The method of claim 64, further comprising adjusting electrical power (5220) delivered to one or more heat sources (2110, 2120, 2121, 2122, 2123, 2140) for heating the elongated fiber tow (100).

69. A method as claimed in claim 64, further comprising rotating (5310) the presser foot device (1100) around a rotation axis (Z), wherein the rotation axis (Z) is orthogonal to the straight foot section (1110) and is included in the groove midplane (1130MP).

70. The method of claim 64, further comprising translating (5320) the presser foot assembly (1100).

71. A method as claimed in claim 64, further comprising translating (5320) and rotating (5310) one or more of the presser foot devices (1100) along a path (7001, 7002, 7003) from a path start point (7001-S) to a path end point (7001-E), wherein the straight foot segment (1110) is collinear with a tangent (7001T) of the path of the presser foot device (1100), and a point of tangency (7001PT) with the path (7001) is included in a mid-plane (1130MP) of the groove.

72. A method as claimed in claim 71, wherein the slender fiber bundle (100) translates in the groove (1130) at a speed that is equal to the speed at which the tangent point (7001PT) of the path (7001) translates along the path.

73. The method of claim 71, further comprising forming a cut (5330) in the elongated fiber bundle (100) at a position (7001-E) where the radius of curvature of the path is one or more of less than 2 mm, less than 3 mm, and less than 5 mm.

74. The method of claim 71, further comprising actuating (5340) a tow cutter assembly (2300) at a position (7001-C, 7002-C, 7003-C) along the path (7001, 7002, 7003), the position (7001-C, 7002-C, 7003-C) being located before the end of the path by a path length (2341) equal to the length (2341) of the elongated fiber tow from the blade (2340) of the tow cutter assembly to the front end (1111) of the straight leg section (1110).

75. The method of claim 71, further comprising unwinding (6406) the elongated fiber tow (100), wherein unwinding comprises rotating (5310) the presser foot assembly (1100).

76. The method of claim 64, further comprising forming a measurement (5350) of a distance (205) between the straight leg segment (1110) and the surface (200) of the object.

77. The method of claim 64, further comprising adjusting (5360) a distance (205) between the straight leg segment (1110) and the surface (200) of the object.

78. The method of claim 64, further comprising adjusting (5370) a distance (206) between a dispenser nozzle outlet (2940) and the surface (200) of the object.

79. The method of claim 78, further comprising adjusting (5380) a distance offset (2980) of the dispenser nozzle outlet (2940) relative to the object surface (200) based on a distance (205) between the straight leg section (1110) and the object surface (200).

80. The method of claim 64, further comprising: translating (5100) the elongated fiber tow (100) within the groove (1130) by a length (110) comprised within the range of 2 mm to 30 mm; and The presser foot device (1100) is guided onto the object surface (200) along a landing trajectory (8010, 8020, 8030).

81. The method of claim 64 further comprises forming (5110) one or more folds along the length of the elongated fiber bundle (100) by passing the fiber tape (90) through one or more grooves (3522G, 3531AG, 3531BG) included in one or more sheaves (3522, 3531A, 3531B).

82. The method of claim 81, wherein one or more of the sheaves (3522, 3531A, 3531B) comprises a rectangular cross-section.

83. The method of claim 64, further comprising obtaining (5120) a measurement of the longitudinal tension of the elongated fiber tow (100) from a tow longitudinal tension detector (2710).

84. The method of claim 83, further comprising adjusting (5130) the speed of the translation (5100) of the elongated fiber tow (100) based on the measured value of the longitudinal tension of the elongated fiber tow (100) from a tow longitudinal tension detector (2710).

85. A computer-readable non-volatile storage device (4120) comprising executable instructions (6000) that, when executed by one or more processors (4110) of a system (2000) for applying an elongated fiber tow (100) to a surface (200) of an object, cause the system (2000) to perform at least the following operations: a) commanding (6100) one or more of the position and speed of the presser wheel motor (2550) to cause the elongated fiber tow (100) to translate along the groove (1130) of the presser foot assembly; and b) commanding (6310) one or more of the position and speed of a second motor (1350) coupled to and rotating the presser foot assembly (1100), wherein The presser foot device (1100) comprises a foot surface (1150) for pressing the elongated fiber bundle (100) onto the object surface (200), The foot surface (1150) includes a straight foot section (1110) for pressing the elongated fiber tow (100) onto the object surface (200), wherein the straight leg section (1110) comprises a rear end (1112) and a front end (1111), wherein the rear end (1112) and the front end (1111) define a front direction (Fx) from the rear end to the front end, and wherein the presser foot device (1100) rotates about a rotation axis (Z), the rotation axis (Z) being orthogonal to the straight foot section (1110) and being included in a groove midplane (1130MP) along a midline (1130ML) of the groove, the midline (1130ML) being included between a left lip (1141) and a right lip (1142) of the groove, The groove includes a flared end that joins the groove to the front end of the straight foot section on the foot surface, and The foot presser device (1100) comprises a hollow foot shaft (1200), in A portion of the hollow axle has an outer diameter and an axis of rotation (Z) and is configured to form a rotational fit within the axle housing (2100).

86. The computer readable non-volatile storage device of claim 85, wherein the speed at which the puck motor (2550) is commanded (6315) is a function of the speed at which the second motor (1350) is commanded (6310).

87. A computer-readable non-volatile storage device as described in claim 85, wherein the instructions (6000) include instructions to command (6315) a tow cutter motor (2355) connected to the tow cutter assembly (2300) and causing the tow cutter assembly to displace a blade (2340) from a first position to a second position.

88. The computer readable non-volatile storage device of claim 87, wherein the instructions (6000) include instructions to adjust the speed (6345) of the pinch roller motor (2550) based on commands sent to the tow cutter motor (2355).

89. The computer readable non-volatile storage device of claim 85, wherein the instructions (6000) include instructions to obtain (6350) rangefinder measurement data from one or more range detector components (2600).

90. The computer-readable non-volatile storage device of claim 89, wherein the instructions (6000) include instructions to adjust (6355) the speed of the puck motor (2550) based on measurements obtained from the one or more ranging detector assemblies (2600).

91. The computer readable non-volatile storage device of claim 85, wherein the instructions (6000) include instructions for acquiring (6120) measurement data from one or more tow longitudinal tension detectors (2710).

92. A computer-readable non-volatile storage device as described in claim 91, wherein the instructions (6000) include instructions to adjust (6130) the speed of the pinch roller motor (2550) based on measurements obtained from one or more of the one or more tow longitudinal tension detectors (2710).

93. A computer-readable non-volatile storage device as described in claim 91, wherein the instructions (6000) include instructions to adjust (6135) the relative speeds of one or more pinch wheel motors (2550) and the tow puller assembly motor (3550) based on measurements obtained from one or more of the one or more tow longitudinal tension detectors (2710).

94. A computer-readable non-volatile storage device as described in claim 85, wherein the instructions (6000) include instructions for storing (6400) one or more digital tool path instructions (7001-S, 7001-1, 7001-2, 7001-3, 7001-E, 7002-S, 7002-1, 7002-2, 7002-E, 7003-S, 7003-1), the one or more digital tool path instructions including one or more of the position and orientation of the presser foot device (1100).

95. A computer-readable non-volatile storage device as described in claim 94, wherein the instructions (6000) include instructions to insert (6405) one or more commands for a tow cutter motor (2355) coupled to a tow cutter assembly (2300) into the digital tool path instructions (7001-S, 7001-1, 7001-2, 7001-3, 7001-E, 7002-S, 7002-1, 7002-2, 7002-E, 7003-S, 7003-1) based on one or more of path length and one or more path curvatures.

96. A computer-readable non-volatile storage device as described in claim 85, wherein the instructions (6000) include instructions to insert (6405) one or more instructions to command the unwinding (6406) of the slender fiber filament bundle (100), the instructions including a command to actuate the second motor (1350).

97. The computer readable non-volatile storage device of claim 85, wherein the instructions (6000) include instructing (6320) one or more motors (3810, 3820, 3830, 3840, 3850, 3910, 3920, 3930) to move at one or more spatial position coordinates (X F 、Y F 、Z F ) and one or more spatial orientation coordinates to configure one or more of the position and speed of the presser foot device (1100).

98. The computer readable non-volatile storage device of claim 85, wherein the instructions (6000) include configuring the position (X) of the presser foot assembly by commanding one or more motors (3820, 3830, 3840, 3850, 3930) based on measurements obtained from one or more ranging detector assemblies (2600). F 、Y F 、Z F 、 θ F , ψ F ) and speed based on one or more of the instructions to adjust (6360) the distance (205) between the straight leg segment (1110) and the object surface (200).

99. A computer-readable non-volatile storage device as described in claim 98, wherein the instructions (6000) include instructions (6360) to adjust the distance (205) between the straight leg segment (1110) and the object surface (200) along the rotation axis (Z) to a value included in the range of 0.05 mm to 1.0 mm.

100. A computer-readable non-volatile storage device as described in claim 98, wherein the instructions (6000) include instructions (6360) for translating and rotating the presser foot device (1100) along a path (7001, 7002, 7003) from a path start point (7001-S, 7002-S) to a path end point (7001-E, 7002-E), wherein the second motor (1350) is commanded so that the straight leg segment (1110) remains colinear with a local tangent (7001T) of the path (7001, 7002, 7003) of the presser foot device (1100), and the tangent point (7001PT) remains included within a segment extending from a front end (1111) of the straight leg segment to a center line (1130ML) of the groove.

101. The computer readable non-volatile storage device of claim 85, wherein the instructions (6000) include commanding one or more motors (3810, 3820, 3830, 3840, 3850, 3910, 3920, 3930, 2930) to move between one or more spatial position coordinates (X F 、Y F 、Z F ) and one or more spatial orientation coordinates ( θ F , ψ F ) at which instructions (6420) are provided for configuring one or more of the positions and velocities of the dispenser nozzle (2940).

102. A computer-readable non-volatile storage device as described in claim 85, wherein the instructions (6000) include instructions (6430) for commanding a dispenser nozzle extension actuator (2930) to adjust one or more of the extended position (2980) and speed of the dispenser nozzle based on one or more of the position (205) and speed of the presser foot device (1100).

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