Apparatus and method for attaching an elongated fiber tow

Abstract

A pressure foot device and system for forming and attaching elongated fiber tows, the pressure foot device comprising: a foot surface having a linear foot segment; a groove having a flared end and defining a center plane of the groove; and a foot shaft housing characterized by a rotation axis of the foot shaft that is perpendicular to the linear foot segment and is contained within the center plane of the groove.

Description

Technical Field

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

Background Art

[0002] Fiber-reinforced plastics (FRP), also called fiber-reinforced polymers, such as plastics reinforced with carbon fibers (CFRP), are materials widely used for lightweight structures ranging from sports equipment to automotive components and aircraft structures. Methods for manufacturing FRP include placing fiber tows, such as prepreg tows, such as tapes, on a substrate. This placement is performed, for example, by a manipulator equipped with a robot, such as a tape dispensing end effector for additive manufacturing. The placement of the tape places constraints on one or more of the speed at which the tape is placed, the trajectory traced by the placement end effector, the radius of curvature of this trajectory, the amount of adhesive polymer used, the amount of air trapped in the FRP, the volume fraction of fibers inside the FRP, the temperature of the placement process, the viscosity of the polymer, and the geometry of the placed layer. The geometry of the placed layer is defined, for example, by its dimensions (e.g., defined by one or more of its length, width, and height), and by the weaving, juxtaposition, and overlay patterns of the tape, such as tape layers. Therefore, there is a need for fiber tows, such as prepreg tows, that enable placement at higher speeds and with greater uniformity than can be achieved using conventional tape placement techniques. There is a need for systems and methods for manufacturing fiber tows. There is also a need for systems and methods for transporting and attaching fiber tows on a surface to form an object. It is also necessary to place fiber tows over a trajectory that includes small radius-of-curvature curves and has an improved ability to pattern a diverse range of fiber layouts.

Summary of the Invention

[0003] In the field of fiber-reinforced plastics, issues relate to the speed at which one or more rovings of fibers can be placed to form a layout. Another issue relates to the accuracy of the layout. A further issue relates to the density of fibers within a given volume that can be achieved to impart strength to the resulting composite material. Accordingly, an object of the present disclosure is to provide embodiments related to systems and methods for manufacturing fiber tows. It is also an object of the present disclosure to provide systems and methods for transporting and attaching fiber tows onto a surface for forming an object. It is also an object of the present disclosure to provide a method for placing a fiber tow over a track including curves with small radii of curvature.

[0004] One embodiment of the present disclosure is a pressure foot device for attaching an elongate fiber tow onto a target surface, the pressure foot device comprising a foot surface for pressing the fiber tow onto the target surface, the foot surface comprising a linear foot segment for pressing the fiber tow onto the target surface, the linear foot segment comprising a rear end and a front end defining a front direction Fx from the rear end to the front end, the foot surface; a groove having a left lip and a right lip for guiding the tow to the foot surface, the groove defining a center plane of the groove as a flat portion along a center line of the groove and extending between the left lip and the right lip of the groove, the groove being coupled onto the front end of the linear foot segment and being oriented at an elevation angle with respect to the linear foot segment; and the groove having a flared end coupled to the foot surface.

[0005] For example, the elevation angle of a part of the groove is 90 degrees. For example, the groove has a flared inlet at the inlet of the groove located at the end opposite to the end of the flared end. For example, the foot surface is on the first side of the central plane of the groove, and has a first toe surface directed at a first elevation angle and a first azimuth angle offset from the front direction Fx, and is on the second side of the central plane of the groove, and has a second toe surface directed at a second elevation angle and a second azimuth angle offset from the front direction Fx, and the first azimuth angle and the second azimuth angle are included within the range of 30 degrees to 90 degrees with respect to the front direction Fx. For example, the first azimuth angle and the second azimuth angle are approximately 90 degrees with respect to the front direction Fx.

[0006] For example, the first toe surface and the second toe surface are in the same plane. For example, the flared end has a chamfer with an elevation angle in the range of 30 degrees to 70 degrees with respect to the front direction Fx. For example, the flared end has a fillet connecting the groove to a linear foot segment. For example, the foot surface is flat. For example, the foot surface has one or more rising contour portions facing the target surface that rise in the Z direction away from the target surface with respect to the linear foot segment when viewed in a cross-section in the Y-Z plane perpendicular to the linear foot segment. For example, one or more of the one or more rising contour portions form a rising curve. For example, one or more of the one or more rising contour portions form a rising straight line. For example, the foot surface is an azimuth sector of a rotating frustum-shaped hollow body, and the axis of the frustum-shaped hollow body is included in the central plane of the groove, and the azimuth sector is included within the range of 180 degrees to 320 degrees. For example, the device has a hollow foot shaft, and the axis of the hollow foot shaft is included on the central plane of the groove. For example, the device has a foot pinion, and the axis of the foot pinion is included on the central plane of the groove. For example, the device has a foot pulley, and the axis of the foot pulley is included on the central plane of the groove.

[0007] For example, the foot surface includes a first material within a first sector proximal to the front end portion and a second material within a second sector distal from the front end portion with respect to the front end portion, and the thermal conductivity of the second material is at most half that of the first material. For example, the foot surface includes a heat sink. For example, the foot surface includes a heat sink forming a surrounding second sector around the first sector proximal to the groove. For example, the flared end portion is proximal to the groove, rises a certain distance above the foot surface, and is separated from the heat sink portion included in the foot surface by the second sector, and includes a first flared end portion, and the second sector forms a heat insulation 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 circular contour sectors that are symmetrically opposite with respect to a central plane and have a groove depth that is greater than or equal to the depth of the radius of the largest circular contour sector. For example, the cross-section of the groove includes one or more U-shaped groove cross-sections that scale down towards the inside of the groove. For example, the groove has a cross-section with two or more linear sides joined by fillets. For example, the distance between the first lip and the second lip of the groove is in the range of 0.2 mm to 2 mm, for example, in the range of 0.2 mm to 1 mm.

[0009] One embodiment of the present disclosure includes a system for attaching an elongated fiber tow to a target surface, the system comprising a pressure foot device. For example, the pressure foot device has a foot surface for pressing the fiber tow onto the target surface, the foot surface comprising a linear foot segment for pressing the fiber tow onto the target surface, the linear foot segment having a rear end and a front end, the rear end and the front end defining a forward direction Fx from the rear end to the front end, a foot surface; and a groove having a left lip and a right lip for guiding the tow onto the foot surface, the groove defining a center plane of the groove as a flat portion along the center line of the groove between the left lip and the right lip of the groove, the groove being coupled onto the front end of the linear foot segment and being oriented at an elevation angle with respect to the linear foot segment, the groove having a flared end that couples to the foot surface, a groove; a foot device comprising; and a foot shaft housing characterized by a rotational axis Z of the foot shaft defining a Z-axis, the rotational axis Z of the foot shaft being perpendicular to the linear foot segment and being included in the center plane of the groove, a foot shaft housing.

[0010] For example, the pressure foot device includes a hollow foot shaft, the axis of the hollow foot shaft being collinear with the rotational axis Z of the foot shaft, and a portion of the shaft forming 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 with infrared radiation directed towards the groove. For example, the foot shaft housing includes one or more induction heating coils. For example, one or more axes of the induction heating coils are parallel to the axis of the rotational axis Z of the foot shaft. For example, the system includes a temperature sensor included in one or more of the foot shaft housing and the pressure foot device.

[0011] For example, the footshaft housing includes a cylindrical sleeve coaxial with the rotation axis Z of the footshaft. For example, the present system includes one or more pinch roller assemblies. For example, one or more of the pinch roller assemblies include a first roller and a second roller, and a common tangent to the first roller and the second roller is on the same straight line as the rotation axis Z of the footshaft. For example, one or more of the pinch roller assemblies include a first roller and a second roller, and one or more of the rollers include a rectangular groove in the outer peripheral portion of the roller. For example, one or more of the pinch roller assemblies include a first roller and a second roller, and one or more of the rollers include a rectangular groove in the outer peripheral portion of the roller, and the cross section of the groove intersects the rotation axis Z of the footshaft.

[0012] For example, the present system includes a cutter assembly having an orifice and a blade, and the orifice intersects the rotation axis Z of the footshaft. For example, the present system includes a cutter assembly having a blade guided by a rail mechanically coupled to a rotatable ring, and the rotation axis of the ring is on the same straight line as the rotation axis Z of the footshaft.

[0013] For example, the system includes a heat exchanger housing disposed between a foot shaft housing and one or more of one or more pinch roller assemblies, the heat exchanger housing having a first through hole, and the axis of the first through hole being collinear with the rotation axis Z of the foot shaft. For example, the heat exchanger housing is disposed between the cutter assembly and the foot shaft housing. For example, the heat exchanger housing includes one or more ducts. For example, the heat exchanger housing includes a duct that forms a turning path of at least 180 degrees around the rotation axis Z of the foot shaft. For example, the heat exchanger housing has a second through hole, and the axis of the second through hole is parallel to the rotation axis Z of the foot shaft. For example, the heat exchanger housing includes a drive shaft that forms a coupling with a pressure foot device. For example, the heat exchanger housing forms a thermally conductive contact with a drive shaft that forms a coupling with a pressure foot device, and the thermal conductance between the two surfaces of the contact is greater than 500 W / m 2 / K. For example, the heat exchanger housing includes a through duct, the through duct having an inlet portion and an outlet portion, and the axis of symmetry of the outlet portion being included in the central plane of the groove.

[0014] For example, a part of the through duct includes a tapered through duct nozzle, the outlet of the tapered through duct nozzle being directed toward the groove, and the axis of symmetry of the outlet being included in the central plane of the groove.

[0015] For example, the system includes one or more distance measurement detector assemblies, each having a rangefinder, one or more of the measurement axes ZR of the rangefinders being directed along a direction parallel to the axis of the rotation axis Z of the foot shaft, the distance from the measurement axis ZR of the distance measurement detector to the rotation axis Z of the foot shaft being greater than the distance from the rotation axis Z of the foot shaft to the rear end portion of the linear foot segment and less than 20 cm. For example, one or more of the one or more distance measurement detector assemblies include a translation stage.

[0016] For example, the present system includes a corn forming assembly, and the corn forming assembly includes one or more grooved wheels, and at least a part of the cross-section of the groove is rectangular. For example, the cross-section of the groove of one or more grooved wheels includes a V-shaped groove inlet and a rectangular groove depth part.

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

[0018] For example, the present system includes a slide head with one or more shafts. For example, one or more of the one or more shafts are intersected by a Z-direction extending groove center plane that extends the center plane of the groove in the Z direction. For example, one or more of the one or more shafts include two orthogonal shafts, and the intersection point of the two orthogonal shafts is generally on the Z-direction extending groove center plane that extends the center plane of the groove in the Z direction.

[0019] For example, the present system includes a support chassis with a cylindrical clamp, and the axis of the cylindrical clamp is parallel to the rotation axis Z of the foot shaft.

[0020] For example, the present system includes one or more of a pinch roller motor coupled to one or more pinch roller assemblies, a corn cutter motor coupled to a corn cutter assembly, and a foot rotation motor coupled to a pressure foot device.

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

[0022] For example, the present system includes a robot support for configuring one or more of the position and velocity of a pressure foot device in one or more spatial positions (X F , Y F , Z F ) and one or more spatial directions (φ F , θ F , ψ F ).

[0023] For example, the present system includes a computer system. For example, the computer system includes 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, one or more of the digital processor, the computer-readable non-volatile storage device, the data bus, and the user interface device, and a communication interface device for transferring data between one or more external systems external to the system, the one or more external systems including one or more of the processor, the storage device, the user interface, the actuator, and the sensor.

[0024] Another embodiment of the present disclosure is a method for attaching an elongated fiber tow to a target surface, the method comprising: translating the elongated fiber tow into a groove of a pressure foot device and onto a foot surface of the pressure foot device in a parallel movement, the groove having a left lip and a right lip and defining a central plane of the groove extending between the left lip and the right lip of the groove along a center line of the groove; guiding the fiber tow within the groove to a flared end of the groove; curving the fiber tow around the flared end of the groove to a linear foot segment included in the foot surface of the pressure foot device, the linear foot segment having a rear end and a front end defining a front direction Fx from the rear end to the front end, the groove being coupled to the front end of the linear foot segment and being oriented at an elevation angle with respect to the linear foot segment; and pressing the fiber tow between the linear foot segment and the target surface.

[0025] For example, one or more of translating, guiding, curving, and pressing the fiber tow includes heating the fiber tow. For example, pressing includes cooling the fiber tow. For example, pressing includes a first step of heating the fiber tow and a second step of cooling the fiber tow. For example, the method includes adjusting the power delivered to one or more heat sources for heating the fiber tow. For example, the method includes rotating a pressure foot device perpendicular to a linear foot segment and about a rotation axis Z included in a center plane of a groove. For example, the method includes translating the pressure foot device. For example, the method includes one or more of translating and rotating the pressure foot device along a path from a start point of the path to an end point of the path, the linear foot segment being collinear with a tangent to the path of the pressure foot device, and a contact point with the path being included in the center plane of the groove. For example, the fiber tow is translated in the groove at a speed equal to the speed at which the contact point with the path translates along the path. For example, the method includes forming a cut in the fiber tow at a position where a radius of curvature of the path is one or more of less than 2 mm, less than 3 mm, and less than 5 mm.

[0026] For example, the method includes operating the cutter assembly at a path length equal to the length of the fiber tow from the blade of the cutter assembly to the front end of the linear foot segment, at a position along the path in front of the end point of the path. For example, the method includes unwinding the tow, which includes rotating the pressure foot device. For example, the method includes measuring the distance between the linear foot segment and the target surface. For example, the method includes adjusting the distance between the linear foot segment and the target surface. For example, the method includes adjusting the distance between the dispenser nozzle and the target surface. For example, the method includes adjusting the offset of the distance of the dispenser nozzle relative to the target surface as a function of the distance between the linear foot segment and the target surface.

[0027] For example, the method includes translating the fiber tow within the groove by a length included in the range of 2 mm to 30 mm and guiding the pressure foot device along a landing trajectory onto the target surface.

[0028] For example, the method includes forming one or more bending portions along the length of the fiber tow by passing a fiber tape through one or more grooves including a rectangular cross-section. For example, forming one or more bending portions includes passing a fiber tape through one or more grooves included on one or more grooved wheels. For example, the method includes obtaining a measurement of the longitudinal tension of the fiber tow from a tow longitudinal tension detector. For example, the method includes adjusting the speed of the parallel movement of the tow as a function of the measurement of the longitudinal tension of the fiber tow from the tow longitudinal tension detector.

[0029] Yet another embodiment of the present disclosure, when executed by one or more processors of a system for attaching an elongated fiber tow onto a target surface, causes the system to at least a) instruct one or more of a position and a speed of a first motor to cause the elongated fiber tow to translate parallel along a groove of a pressure foot device; and b) instruct one or more of a position and a speed of a second motor coupled to the pressure foot device to cause the pressure foot device to rotate. The computer-readable non-volatile storage device includes executable instructions. The pressure foot device includes a foot surface for pressing the fiber tow onto the target surface. The foot surface includes a linear foot segment for pressing the fiber tow onto the target surface. The linear foot segment includes a rear end and a front end that define a front direction Fx from the rear end to the front end. The pressure foot device rotates about a rotation axis Z that is perpendicular to the linear foot segment and is included within a central plane of the groove along a center line of the groove included between a left lip and a right lip of the groove.

[0030] For example, the instructions include instructions for the speed at which the first motor is instructed to be a function of the speed at which the second motor is instructed. For example, the instructions include instructions to instruct a third motor coupled to the tow cutter assembly to displace a blade of the tow cutter assembly from a first position to a second position.

[0031] For example, the instructions include instructions for adjusting the speed of the first motor as a function of an instruction sent to the third motor. For example, the instructions include instructions for obtaining distance measurement data from one or more distance measurement detector assemblies. For example, the instructions include instructions for adjusting the speed of the first motor as a function of measurements obtained from one or more distance measurement detector assemblies. For example, the instructions include instructions for obtaining measurement data from one or more tow longitudinal tension detectors.

[0032] For example, this instruction includes an instruction for adjusting the speed of one or more first motors as a function of measurements obtained from one or more of one or more ear longitudinal tension detectors. For example, this instruction includes an instruction for adjusting the relative speed of one or more first motors as a function of measurements obtained from one or more of one or more ear longitudinal tension detectors. For example, this instruction includes an instruction for storing an instruction for a numerical tool path including one or more of the position and orientation of a pressure foot device.

[0033] For example, this instruction includes an instruction for inserting one or more instructions regarding a third motor coupled to an ear cutter assembly into an instruction for a numerical tool path as a function of one or more of the path length and the curvature of one or more paths. For example, this instruction includes an instruction for inserting one or more instructions for instructing to unwind the ear, and this instruction includes an instruction for activating a second motor. For example, this instruction includes one or more spatial position coordinates X F Y F Z F and includes an instruction for instructing one or more motors to configure one or more of the position and speed of the pressure foot device in one or more spatial direction coordinates.

[0034] For example, this instruction includes the position (X F Y F Z F φ F θ F ψ FIt includes instructions for adjusting the distance between the linear foot segment and the target surface by instructing one or more motors to configure one or more of the distance and speed. For example, the instructions include instructions for adjusting the distance between the linear foot segment along the rotation axis Z and the target surface to a value included in the range from 0.05 mm to 1.0 mm.

[0035] For example, this instruction includes instructions for translating and rotating the pressure foot device along the path from the start point to the end point of the path. The second motor is instructed so that the linear foot segment remains on the same straight line as the local tangent of the path of the pressure foot device, and the contact point remains included within the segment extending from the front end of the linear foot segment to the length of the center line of the groove.

[0036] For example, this instruction includes instructions for instructing one or more motors to configure one or more of the position and speed of the dispenser nozzle in one or more spatial position coordinates (X F , Y F , Z F ) and one or more spatial direction coordinates (φ F , θ F , ψ F ). For example, this instruction includes instructions for instructing the dispenser nozzle extension actuator to adjust one or more of the extension position and speed of the dispenser nozzle as a function of one or more of the position and speed of the pressure foot device.

Brief Description of the Drawings

[0037]

Figure 1A

Figure 1B

Figure 1C

Figure 1D

Figure 1E

Figure 1F

Figure 1G

Figure 1H

Figure 1I

Figure 1J

Figure 1K

Figure 1L

Figure 1M

Figure 1N

Figure 1O

Figure 1P

Figure 2A

Figure 2B

Figure 3

Figure 4A

Figure 4B

Figure 4C

Figure 5

Figure 6A

Figure 6B

Figure 6C

Figure 6D

Figure 6E

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

DETAILED DESCRIPTION OF THE INVENTION

[0038] Figures 1A through 1P provide exemplary embodiments 1001, 1001S, 1002B, 1003S, 1004B, 1005, 1006S, 1006, 1007G, 1008G, 1009G, 1010, 1011S, 1012, 1013 of a pressure foot device 1100 for attaching an elongated fiber tow 100. For example, a pressure foot device 1100 for attaching an elongated fiber tow 100 to a target surface 200, the pressure foot device 1100 including a foot surface 1150 for pressing the fiber tow 100 onto the target surface 200, the foot surface 1150 including a linear foot segment 1110 for pressing the fiber tow 100 onto the target surface 200, the linear foot segment 1110 including a rear end portion 1112 and a front end portion 1111 that define a forward direction Fx from the rear end portion to the front end portion; 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 defining a center plane 1130MP of the groove as a flat portion along a center line 1130ML of the groove and extending between the left lip 1141 and the right lip 1142 of the groove, the groove 1130 joining onto the front end portion 1111 of the linear foot segment 1110 and being oriented at an elevation angle 1130A with respect to the linear foot segment 1110; and the groove 1130 including a flared end portion 1120 that joins to the foot surface 1150. For example, an elevation angle 1130A of a portion of the groove 1130 is 90 degrees. For example, the groove 1130 includes a flared inlet 1133 at an inlet 1130E of the groove, the inlet 1130E being located at an end of the groove opposite an end of the flared end portion 1120. In some embodiments, the groove 1130 includes one or more closed portions that form, for example, a channel.

[0039] For example, the foot surface 1150 is on the first side of the groove center plane 1130MP and includes a first toe surface 1161 directed at a first elevation angle 1161A1 and a first azimuth angle 1161A2 offset from the front direction Fx, and a second toe surface 1162 on the second side of the groove center plane 1130MP and directed at a second elevation angle 1162A1 and a second azimuth angle 1162A2 offset from the front direction Fx. The first azimuth angle 1161A2 and the second azimuth angle 1162A2 are within the range of 30 degrees to 90 degrees with respect to the front direction Fx. For example, the first azimuth angle 1161A2 and the second azimuth angle 1162A2 are approximately 90 degrees with respect to the front direction Fx. For example, the first toe surface 1161 and the second toe surface 1162 are in the same plane. For example, the flared end 1120 includes a chamfer 1125 having an elevation angle 1125A in the range of 30 degrees to 70 degrees with respect to the front direction Fx. For example, the flared end 1120 includes a fillet 1120F that connects the groove 1130 to the linear foot segment 1110. For example, the foot surface 1150 is flat. For example, when viewed in a cross-section in the Y-Z plane perpendicular to the linear foot segment 1110, the foot surface 1150 includes one or more rising contour portions 1171, 1172 that rise in the Z direction away from the target surface 200 with respect to the linear foot segment 1110 and face the target surface 200.

[0040] Figure 1O is a perspective view of a pressure foot device 1100 having one or more curved rising contour portions 1171, 1172. For example, one or more of the one or more rising contour portions 1171, 1172 form rising curves 1171C, 1172C. Figure 1P is a perspective view of a pressure foot device 1100 having one or more linear rising contour portions 1171, 1172. For example, one or more of the one or more rising contour portions 1171, 1172 form rising straight lines 1171L, 1172L.

[0041] For example, the foot surface 1150 is an azimuth sector 1150A of a rotating frustum-shaped hollow body, and the axis of the frustum-shaped hollow body is included in the central plane 1130MP of the groove, and the azimuth sector 1150A is included in the range of 180 degrees to 320 degrees. For example, the device 1100 includes a hollow foot shaft 1200, and the axis of the hollow foot shaft 1200 is included on the central plane 1330MP of the groove.

[0042] For example, the present device includes a foot pinion 1210, and the axis of the foot pinion 1210 is included on the central plane 1330MP of the groove. For example, the foot pinion 1210 is provided with an orifice 1211 on its rotation axis, for example, for the passage of the fiber tow 100. For example, the foot pinion 1210 is provided with one or more fixed points 1212, for example, rails, for adjusting the position of the pressure foot device 1100 with respect to the orifice 1211 of the foot pinion, for example, for adjusting the position of the groove 1130. For example, another embodiment of the pressure foot device 1100 is an integral part formed of, for example, a single, milled or molded component, and has the characteristics of the pressure foot device 1100 and the pressure foot pinion 1210. For example, it is formed as a pressure foot device provided with a plurality of pinion teeth forming a pinion, and its axis is included in the central plane 1130MP of the groove.

[0043] For example, the device includes a foot pulley 1220, and the axis of the foot pulley 1220 is included on the center plane 1330MP of the groove. For example, the foot pulley 1220 includes an orifice 1221 on its rotation axis, for example, for the passage of the fiber tow 100. For example, the foot pulley 1220 includes one or more fixed points 1222, such as rails, for adjusting the position of the pressure foot device 1100 with respect to the orifice 1221 of the foot pulley, for example, for adjusting the position of the groove 1130. For example, another embodiment of the pressure foot device 1100 is an integral part formed of, for example, a single, milled or molded component, and includes the features of the pressure foot device 1100 and the pressure foot pulley 1220, and its axis is included in the center plane 1130MP of the groove.

[0044] For example, the foot surface 1150 includes a first material in a first sector 1151 proximal to the front end with respect to the front end, and a second material in a second sector 1152 distal from the front end with respect to the front end, and the thermal conductivity of the second material is less than or equal to half of the thermal conductivity of the first material. One or more of the first material and the second material include, for example, alloy steel, such as hardened steel, such as DIN 1.3505 steel, such as DIN 1.3343 steel, and alloys including one or more of copper, aluminum, iron, nickel, tin, titanium, tungsten, vanadium, and zinc, such as metal alloys, and ceramics, glass, and polymers. In some embodiments, the foot surface includes a coating, for example, a coating including one or more of metal, hardened metal, metal oxide, ceramic, polymer, such as polytetrafluoroethylene. For example, the foot surface has a Rockwell scale hardness of HRC55 or higher.

[0045] Figure 1M is a perspective view of a pressure foot device 1100 with a heat sink 1155, and Figure 1N is a cross-sectional side view of the pressure foot device 1100 with the heat sink 1155. For example, the foot surface 1150 includes the heat sink 1155. For example, the heat sink includes a plurality of blades 1155B, such as equally spaced blades. For example, the blades are blown by an air supply source including, for example, one or more ducts 1155D, such as ducts directed towards the plurality of blades 1155B. For example, the foot surface 1150 includes the heat sink 1155 forming a surrounding second sector around a first sector 1151 proximal to the groove 1130.

[0046] For example, the flared end 1120 is proximal to the groove 1130, rises from the foot surface 1150 by a distance 1115Z, and is separated from the heat sink portion 1155 included in the foot surface 1150 by a second sector 1152. The second sector 1152 forms a heat insulation portion between the first flared end portion 1120-1 and the foot surface 1150. For example, the heat insulation portion of the second sector 1152 includes one or more of a sandwich structure including a heat insulating material, such as ceramic, glass, polymer, polymer foam, elastomer, and foam. For example, the second sector 1152 limits the thermal conductivity from the first flared end portion 1120-1 to the heat sink portion 1155 to a value less than 500 W / m 2 / K. For example, the second sector 1152 has a structure with a plurality of ribs, such as a structure with cutouts, that mechanically connect the first flared end portion 1120-1 to the heat sink portion 1155.

[0047] FIG. 1J is a bottom view of a pressure foot device 1100 with grooves, and the cross-section of this groove includes one or more pairs of circular contour sectors that are symmetrically opposite. For example, the cross-section of the groove includes one or more pairs of circular contour sectors 1130C11, 1130C12, 1130C21, 1130C22 that are symmetrically opposite with respect to the central plane 1130MP and are included in a groove depth greater than or equal to the depth of the radius 1130MR of the largest circular contour sector. For example, the cross-section of the groove includes a second pair of circular contour sectors 1130C21, 1130C22 that are located at a groove depth greater than the depth of the first pair of circular contour sectors 1130C11, 1130C12 on the opposite side along, for example, the central plane 1130MP of the groove.

[0048] FIG. 1K is a bottom view of a pressure foot device 1100 with grooves, and the cross-section of this groove includes one or more U-shaped groove cross-sections that scale down towards the inside of the groove. For example, the cross-section of the groove includes one or more U-shaped groove cross-sections 1130U1, 1130U2 that scale down towards the inside of the groove 1130 along, for example, the central plane 1130MP of the groove. For example, an embodiment of the U-shaped groove 1130 includes a semi-circular portion that connects each side of the U. Other embodiments include, for example, one or more of an elliptical portion, a parabolic portion, and a rounded portion that connect each side of the U.

[0049] FIG. 1L is a bottom view of a pressure foot device 1100 with grooves, and the cross-section of this groove includes two or more linear sides connected by a fillet. For example, the groove 1130 has a cross-section that includes two or more linear sides 1130S1, 1130S2 connected by a fillet 1130F. For example, the two or more linear sides 1130S1, 1130S2 are symmetrically arranged with respect to the central plane 1130MP of the groove. For example, an embodiment of the cross-section of the groove forms a semi-rectangle with rounded corners.

[0050] For example, the distance between the first lip 1141 and the second lip 1142 of the groove is in the range of 0.2 mm to 2 mm, for example, in the range of 0.2 mm to 1 mm.

[0051] For example, a groove 1130 including a width, shown as a lip-to-lip distance 1130W between the first lip 1141 and the second lip 1142 of the groove, that is approximately equal to the width 100W of the tooth 100 (e.g., 2% to 20%, for example, 5% to 15% margin larger than the width of the tooth 100) including a rectangular cross-section restricts and guides the orientation of the tooth 100 according to the orientation of the center plane 1130MP of the groove and provides a method for restricting and guiding the orientation of the linear foot segment 1110 by an extension portion. For example, the lip-to-lip distance 1130W is larger than the width 100W of the tooth 100 by a margin included in the range of 2% to 500%, for example, in the range of 2% to 300%, for example, in the range of 5% to 150%. For example, a tooth 100 having a width 100W of about 0.4 mm is conveyed into a groove 1130 having a lip-to-lip distance 1130W in the range of 0.5 mm to 2 mm, for example, 1 mm. For example, the width 100W of the tooth 100 is formed and defined by the width 3531BW of the groove 3531BG of the grooved wheel 3531B (FIG. 6D) of the tooth-forming assembly 3000 (FIG. 6A). Regarding another exemplary embodiment, a tooth 100 having a width 100W of about 0.8 mm is conveyed within a groove 1130 having a lip-to-lip distance 1130W in the range of 1 mm to 2 mm, for example, 1 mm.

[0052] For example, the method of rotating the pressure 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 as the tow 100 translates relative to the object 200 provides a way to increase the adhesion surface of the tow 100 onto the target surface 200 and increase the adhesion force between the tow 100 and the target surface compared to a non-rotated tow. For example, the method 5000 (FIG. 12) for attaching an elongated fibrous tow includes rotating the pressure foot device 1100, such that, for example, the rotation angle matches the tangent 7001PT to the path of the pressure foot device 1100 (FIG. 14). For example, the method 5000 including rotating the tow 100 as the tow 100 is attached to the curved path 7001-2 onto the target surface 200 reduces the probability that the tow will separate from the target surface 200 and form a shortcut to the desired path for the tow. For example, the method 5000 of rotating the tow 100 within a groove 1300 that is approximately the same width as the tow 100 prevents a reduction in the positioning accuracy of the tow, which occurs, for example, by the lateral position of the tow unexpectedly jumping as observed in a system that supplies and translates the tow or filament within a channel that is substantially larger than the width of the tow 100.

[0053] Figure 2A is a perspective view of a system 2000 for attaching an elongated fiber tow, comprising a pinion-driven pressure foot device 1100, a foot shaft housing 2100 with one or more heat sources 2110, and a heat exchanger housing 2200. Figure 4A provides a cross-section of the system 2000 for attaching the elongated fiber tow 100 to a target surface 200, the system comprising the pressure foot device 1100. For example, the pressure foot device 1100 has a foot surface 1150 for pressing the fiber tow 100 onto the target surface 200, the foot surface 1150 comprising a linear foot segment 1110 for pressing the fiber tow 100 onto the target surface 200, the linear foot segment 1110 having a rear end 1112 and a front end 1111 that define a forward direction Fx from the rear end to the front end, the foot surface 1150; a groove 1130 having a left lip 1141 and a right lip 1142 for guiding the tow to the foot surface 1150, the groove 1130 defining a center plane 1130MP of the groove as a flat portion along a center line 1130ML of the groove between the left lip 1141 and the right lip 1142 of the groove 1130, the groove 1130 being joined onto the front end 1111 of the linear foot segment 1110 and being oriented at an elevation angle 1130A with respect to the linear foot segment 1110, the groove 1130 having a flared end 1120 joined to the foot surface 1150; a foot shaft housing 2100 characterized by a rotational axis Z of the foot shaft defining the Z-axis, the rotational axis Z of the foot shaft being perpendicular to the linear foot segment 1110 and being included in the center plane 1130MP of the groove.

[0054] For example, the pressure foot device 1100 includes a hollow foot shaft 1200. The axis of the hollow foot shaft 1200 is collinear with the rotation axis Z of the foot shaft, and a part of the shaft forms a sliding fit within the foot shaft housing 2100. For example, the hollow foot shaft 1200 has a through hole that is coaxial with the outer diameter of the hollow foot shaft 1200. In some embodiments of the hollow foot shaft 1200, a part of the shaft forms a running 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 one or more electric resistance change type elements and one or more induction elements formed as, for example, one or more coils 2120, 2121, 2122, 2123.

[0055] For example, the system 2000 includes a radiation source 2140 with infrared radiation directed towards the groove 1130. For example, the radiation source 2140 is included in a plane from the rotation axis Z of the foot shaft to the radiation source 2140 that is in the same plane as the central plane 1130MP of the groove. For example, the radiation source 2140 includes one or more electric resistance change type elements with, for example, one or more rods directed in a direction that is in the same plane as the rotation axis Z of the foot shaft. For example, the radiation source includes a radiation reflector directed to reflect radiation towards one or more of, for example, the groove 1130, the flared end 1120, and the target surface 200. For example, the radiation source 2140 includes one or more optical fibers that guide radiation emitted by, for example, one or more lasers towards one or more of the groove 1130, the flared end 1120, and the target surface 200.

[0056] Figures 3A and 3B are top views of a foot shaft housing 2100 having one or more induction coils as heat sources 2120, 2121, 2122, 2123 for a pressure foot device 1100 therebelow. For example, the foot shaft housing 2100 includes one or more induction heating coils 2120, 2121, 2122, 2123. For example, one or more axes of the induction heating coils 2120, 2121, 2122, 2123 are parallel to the axis of the rotation axis Z of the foot shaft.

[0057] For example, the system includes temperature sensors 1170, 2170, 2270 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 rotation axis Z of the foot shaft.

[0058] For example, the system 2000 includes one or more pinch roller assemblies 2500.

[0059] Figure 4B is a top view of a roller of a pinch roller assembly 2500 included in a system for attaching an elongated fiber tow 100. For example, one or more of the pinch roller assemblies 2500 include a first roller 2510-1 and a second roller 2510-2, and a common tangent line between the first roller and the second roller is on the same straight line as the rotation axis Z of the foot shaft. For example, in some embodiments, the common tangent line between the first roller and the second roller intersects the rotation axis Z of the foot shaft.

[0060] For example, one or more of the pinch roller assemblies 2500 include a first roller 2510-1 and a second roller 2510-2, and one or more of the rollers 2510-1, 2510-2 have a rectangular groove 2510G in an outer side portion of the roller. For example, a cross-section of the groove intersects a 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 separated from the other roller or retracted with respect to the other roller by, for example, a user acting on a roller support handle 2510H (shown in FIG. 5). For example, one or more rotation axes of the rollers are supported by the roller support handle 2510H.

[0061] For example, the system 2000 includes an inlet 2415 that includes one or more of, for example, a tube and an internal cylindrical geometry for receiving a funnel shape for guiding a filament, such as a roving or tow, that includes one or more bending portions along a longitudinal axis, such as the Z axis, and a cylindrical conduit 2417 for straightening the filament and guiding it from the inlet 2415 into the groove 2510G.

[0062] For example, the system 2000 includes an orifice 2350 -O and a tow cutter assembly 2300 including a blade 2340, and the orifice 2350 -O intersects the rotation axis Z of the foot shaft. For example, an embodiment of the tow cutter assembly 2300 includes an ultrasonic cutter, such as a blade operated at one or more ultrasonic frequencies.

[0063] For example, the system 2000 includes a tow cutter assembly 2300 including a blade 2340 guided by a rail 2330 mechanically coupled to a rotatable ring 2320, and a rotation axis of the ring is collinear with the rotation axis Z of the foot shaft. For example, the rotatable ring includes one or more of, for example, a gear, a pulley, and a motor, such as a stepper motor2350 and is coupled to a drive assembly 2310 having

[0064] For example, system 2000 includes a heat exchanger housing 2200 disposed between a foot shaft housing 2100 and one or more of one or more pinch roller assemblies 2500. The heat exchanger housing 2200 includes a first through hole 2250, and the axis of the first through hole is collinear with the rotation axis Z of the foot shaft. In some embodiments of system 2000, a temperature sensor 2270 is included in the heat exchanger housing 2200. For example, the heat exchanger housing 2200 is disposed between a cutter assembly 2300 and a foot shaft housing 2100.

[0065] FIG. 4C is a top cross-sectional view of a heat exchanger housing 2200 including one or more ducts 2210. For example, the heat exchanger housing 2200 includes one or more ducts 2210. For example, one or more ducts 2210 include one or more duct ports 2215 having, for example, a controllable valve or vane for regulating the flow of fluid flowing through the interior of one or more ducts 2210. For example, the heat exchanger housing 2200 includes a duct 2210 that forms a turning path of at least 180 degrees around the rotation axis Z of the foot shaft. For example, the duct forms one or more semi-circular loops around the rotation axis Z of the foot shaft. For example, the heat exchanger housing 2200 includes a second through hole 2252, and the axis of this second through hole 2252 is parallel to the rotation axis Z of the foot shaft. For example, the heat exchanger housing 2200 includes a drive shaft 1360 that forms a coupling with a pressure foot device 1100. For example, the drive shaft includes a pinion 1310 coupled to a pressure foot pinion 1210. With respect to another example, as shown in FIG. 2B, the drive shaft includes a pulley 1320 coupled to a pressure foot pulley 1220.

[0066] For example, the heat exchanger housing 2200 forms a thermally conductive contact 1370 with the drive shaft 1360 that forms a coupling with the pressure foot device 1100, and the interfacial conductance between the two surfaces of the contact is greater than 500 W / m 2 / K.

[0067] For example, the heat exchanger housing 2200 further includes a duct 2400, the duct includes an inlet portion 2410 and an outlet portion 2420, and the axis of symmetry of the outlet portion is included in the central plane 1130MP of the groove.

[0068] For example, a part of the duct 2400 includes a tapered duct nozzle or funnel shape 2420, the outlet 2420-O of the tapered duct nozzle is directed toward the groove 1130, and the axis of symmetry of the outlet 2420-O is included in the central plane 1130MP of the groove. For example, the duct 2400 includes an outlet duct 2430 aligned with the rotation axis Z of the foot shaft, for example. This outlet duct 2430 has an inner diameter smaller than the inner diameter of a part of the duct 2400 included between the rollers 2510-1, 2510-2 and the duct nozzle or funnel shape 2420, for example. For example, the system 2000 includes a duct extension portion 2440, and the axis of this duct extension portion 2440 is aligned with the rotation axis Z of the pressure foot device. For example, the duct extension portion is aligned with the duct 2400. In some embodiments, the duct extension portion passes through, for example, one or more of the through hole 2250, the foot shaft housing 2100, and a part of the pressure foot device 1100. For example, a part of the pressure foot device passes through the foot shaft housing 2100.

[0069] For example, the system 2000 includes one or more distance measurement detector assemblies 2600, each having a rangefinder 2650, and one or more of the measurement axes ZR of the rangefinder are oriented along a direction parallel to the axis of the rotation axis Z of the foot shaft. The distance 2630 from the measurement axis ZR of the distance measurement 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 portion 1112 of the linear foot segment and less than 20 cm.

[0070] For example, one or more of the one or more distance measurement 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 distance measurement detector assemblies 2600 relative to the pressure foot device 1100.

[0071] For example, system 2000 includes a corn forming assembly 3000 supported by, for example, a corn forming assembly chassis 3100. For example, the corn forming assembly chassis 3100 includes one or more of a tape guiding and tension adjusting assembly 3510, a tape preheating assembly 3520, a tape heater 3543, a corn forming assembly 3530, and a corn heating assembly 3540. For example, the corn forming assembly 3000 includes one or more grooved wheels 3522, 3531A, 3531B, and at least a part of the cross-section of the groove is rectangular. For example, the corn forming assembly 3000 includes a tape guiding and tension adjusting assembly 3510, which includes, for example, a wheel 3511, for example, has a groove with a flat bottom, and is configured to apply a load on the tape 90, for example, via a weight, a spring, or a servo motor. For example, the corn forming assembly 3000 includes a tape preheating assembly 3520. For example, the tape preheating assembly 3520 includes one or more of a first grooved wheel 3522 having, for example, a groove 3522G with a flat bottom, and a wheel cooler 3522C. For example, the wheel cooler includes one or more of an air blower having, for example, an air supply part and one or more orifices in the chassis 3100 of the corn forming assembly, and a cooling bath containing, for example, water.

[0072] For example, the corn forming assembly 3000 includes a tape post-heating assembly or a first corn forming assembly 3530. For example, the cross-section of the groove of one or more second grooved wheels 3531A, 3531B includes a V-shaped groove inlet 3531E and a rectangular groove depth part 3531D. For example, the tape 90 is bent into a corn 100 in the second grooved wheel 3531A. For example, the first corn forming assembly 3530 includes a wheel cooler 3522C.

[0073] For example, system 2000 includes one or more infrared radiation sources 3542, 3543 directed at the path of the ear 100. For example, the tape heating source of infrared radiation 3543 is included between the first grooved wheel 3522 and the second grooved wheel 3531A. For example, the ear heating assembly 3540, such as having an ear heating source of infrared radiation 3542, is included downstream of one or more ears of the second grooved wheels 3531A, 3531B, for example, in the ear heating assembly 3540 of the ear forming assembly 3000. For example, the ear heating source of infrared radiation 3542 includes an aperture 3542A related to one or more of inserting the ear, enabling visual monitoring of the ear, and heating only a part of the outer periphery of the ear.

[0074] For example, system 2000 includes an ear traction assembly 3500. For example, the ear traction assembly is located downstream of the ear in the chassis 3100 of the ear forming assembly. For example, the ear traction assembly 3500 includes one or more pinch roller assemblies 3501, 3502, 3503, for example, three pinch roller assemblies. For example, one or more pinch roller assemblies 3501, 3502, 3503 are driven by an ear traction assembly motor 3550. For example, the ear traction assembly 3500 includes one or more of, for example, a wheel encoder or resolver attached to one or more of the pinch rollers, and, for example, an optical sensor for monitoring the ear, as one or more of, for example, a speed sensor for measuring or estimating the speed of the ear, a tension sensor attached to one or more of the pinch rollers, and, for example, a motor power sensor for estimating the tension of the ear.

[0075] For example, system 2000 includes a dough buffer assembly 3600. For example, the dough buffer assembly 3600 includes one or more flexible pipe assemblies having a first tube 3610 and a second tube 3620, the outer diameter of the first tube being less than the inner diameter of the second tube, and the first tube can be slid and inserted into the second tube. For example, the buffer assembly 3600 where the outer diameter of the first tube is smaller than the inner diameter of the second tube allows the first tube 3610 and the second tube 3620 to slide relative to each other in a nested manner as the tension of the dough 100 continuously increases and decreases as the dough 100 is supplied by the dough forming assembly 3000 and demanded by the pinch wheel assembly 2500. For example, the first tube 3610 and the second tube 3620 slide into each other's interiors in a nested manner to form a loop 3655. For example, the dough inlet of the first tube 3610 is moored by a first fastener 3610F. For example, the dough outlet of the second tube 3620 is moored by a second fastener 3620F. For example, one or more of the first tube 3610 and the second tube 3620 are restricted by a one-way restricting means 3650 so as to allow motion of the tubes 3610, 3620 in a single direction, for example, in the radial direction of the loop. For example, the one-way restricting means 3650 includes one or more restricting rollers 3651, for example, two restricting rollers 3651. For example, the restricting roller 3651 is mounted to slide on a rail 3652 that is oriented, for example, in the radial direction of the loop, for example, in the vertical direction, for example, perpendicular to the direction in which the dough exits the dough forming assembly 3000. For example, one or more of the restricting rollers 3651 are loaded with a spring along the direction of the rail. In some embodiments, the one-way restricting means 3650 includes a sensor, for example, a position sensor, for example, a strain gauge, so as to detect one or more of the tension and geometry of the loop.

[0076] For example, system 2000 includes a corn longitudinal tension detector 2710. For example, tension detector 2710 is configured to contact corn 100 at a first end and coupled at a second end to a force measurement sensor, such as a strain gauge, and includes, for example, one or more wheels, such as one or more sliders.

[0077] For example, system 2000 includes a slide head 2800 having one or more shafts 2810, 2820. For example, slide head 2800 includes a first shaft 2810 that is perpendicular to a second shaft 2820. For example, one or more of the one or more shafts 2810, 2820 are intersected by a center plane 1130MPZ of a groove extending in the Z direction that extends the center plane 1130MP of the groove in the Z direction.

[0078] For example, one or more of the one or more shafts 2810, 2820 include two orthogonal shafts 2810, 2820, and an intersection point of the two orthogonal shafts 2810, 2820 is generally on a center plane 1130MPZ of a groove extending in the Z direction that extends the center plane 1130MP of the groove in the Z direction. For example, the intersection point is included within a radius from the Z axis equal to three diameters of the shaft with the largest diameter.

[0079] For example, system 2000 further includes a support chassis having a cylindrical clamp 2620, and an axis of the cylindrical clamp 2620 is parallel to a rotation axis Z of a foot shaft.

[0080] For example, system 2000 includes one or more of a pinch roller motor 2550 coupled to one or more pinch roller assemblies 2500, a corn cutter motor 2350 coupled to a corn cutter assembly 2300, and a foot rotation motor 1350 coupled to a pressure foot device 1100.

[0081] For example, system 2000 further includes a dispenser nozzle outlet 2940 for dispensing a thermoplastic material onto the target surface 200. For example, the dispenser nozzle outlet is adapted to dispense a thermoplastic material. This thermoplastic material includes one or more of a metal, such as a metal powder, fibers finely chopped, such as fibers including finely chopped carbon fibers, a silicate, such as sand, a ceramic, a powder, such as a carbon black powder, silicon, a foam, such as a urethane, polyurethane, polystyrene foam, and an elastomer.

[0082] For example, system 2000 includes a dispenser nozzle assembly 2900. For example, the dispenser nozzle assembly 2900 includes an inlet 2915 having one or more of a tube for guiding a filament, such as a thermoplastic filament, and an internal cylindrical geometry for receiving a funnel shape, one or more rollers 2910-1, 2910-2 having, for example, a groove 2910G on the outer side thereof and driven by a pinch roller motor 2950, and a cylindrical conduit 2917 for straightening a material filament and guiding it from the inlet 2915 to the groove 2910G, and a duct 2920, such as a duct for guiding the material filament to the nozzle 2940.

[0083] For example, system 2000 includes a dispenser nozzle extension actuator 2930 for adjusting the Z-axis position of the outlet 2940 of the dispenser nozzle.

[0084] For example, the Z-axis position of the outlet 2940 of the dispenser nozzle is offset by an offset 2980 included in the range from -4 mm to +4 mm from the Z-axis position of the linear foot segment 1110.

[0085] FIG. 9 is a perspective view of a system 2000 for attaching an elongated fiber tow, mounted on a robotic manipulator 3800. For example, the system 2000 configures one or more of the position and velocity of the pressure foot device 1100 in one or more spatial positions (X F , Y F , Z F ) and one or more spatial directions (φ F , θ F , ψ F ). For example, the robotic support includes one or more motors 3810, 3820, 3830, 3840, 3850 that actuate one or more joints to configure a pressure foot device, for example, disposed at the position of the end effector of the robot, in a certain spatial position and orientation.

[0086] FIG. 11 provides a block diagram of a computer system 4000. For example, the system 2000 includes a computer system 4000. For example, the computer system 4000 includes one or more of 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 of the 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 a communication interface device 4140. The communication interface device 4140 is for transferring data between one or more of 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 external to the system, which include one or more of a processor, a storage device, a user interface, an actuator, and a sensor.

[0087] FIG. 12 is a block diagram of a method 5000 for attaching an elongated fiber tow 100 to a target surface 200, e.g., a block diagram of a computer-based method including computer-readable instructions stored on a non-transitory recording medium, the method comprising: translating 5100 the elongated fiber tow 100 into the groove 1130 of the pressure foot device 1100 and onto the foot surface 1150 of the pressure foot device 1100, the groove 1130 having a left lip 1141 and a right lip 1142 and defining a center plane 1130MP of the groove extending between the left lip 1141 and the right lip 1142 of the groove along a center line 1130ML of the groove; guiding 5200 the fiber tow within the groove to the flared end 1120 of the groove; curving 5230 the fiber tow around the flared end of the groove to a linear foot segment 1110 included in the foot surface 1150 of the pressure foot device, the linear foot segment 1110 having a rear end 1112 and a front end 1111 defining a front direction Fx from the rear end to the front end, the groove 1130 being coupled to the front end of the linear foot segment 1110 and being oriented at an elevation angle 1130A with respect to the linear foot segment; and pressing 5240 the fiber tow between the linear foot segment and the target surface 200.

[0088] For example, one or more of translating 5100, guiding 5200, curving 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 with a distal or heat sink portion 1155 (with respect to the groove 1130) of the pressure foot device 1100, e.g., pressing the fiber tow 100. 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.

[0089] For example, method 5000 includes adjusting 5220 the power delivered to one or more heat sources 2110, 2120, 2121, 2122, 2123, 2140 for heating the fiber tow 100.

[0090] For example, method 5000 includes rotating 5310 the pressure foot device 1100 about a rotation axis Z that is perpendicular to the linear foot segment 1110 and is included in the center plane 1130MP of the groove. For example, method 5000 further includes translating 5320 the pressure foot device 1100.

[0091] FIG. 14 is a top view of an object 7000 having a layer 7100 of tows including a plurality of fiber tow segments 101, 102, 103. For example, method 5000 further includes one or more of translating 5320 and rotating 5310 the pressure foot device 1100 along paths 7001, 7002, 7003 from a start point 7001-S to an end point 7001-E of the path, the linear foot segment 1110 being collinear with a tangent 7001T to the path of the pressure foot device 1100, and a contact point 7001PT with respect to the path 7001 being included within the center plane 1130MP of the groove. For example, method 5000 includes translating and rotating simultaneously. The method of forming the helical path 7300 includes forming one or more paths that form a helical arrangement, for example, paths 7001, 7002, 7003 arranged in succession. For example, method 5000 includes forming an internal region 7500, also referred to as a filling portion 7500, that fills an area or volume within one or more of the outer contours formed by the paths 7001, 7002, 7003 of the object 7000, for example, within a plurality of stacked rows or layers 7100.

[0092] For example, the fiber tow 100 is translated within the groove 1130 at a speed equal to the speed at which the contact point 7001PT with the path 7001 translates along the path.

[0093] For example, method 5000 further includes forming a cut 5330 of fiber tow 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. For example, the radius of curvature of the path is a path planned by one or more path instructions, such as generated by a computer-based path planning system. For example, the path is segmented at a position where the planned path has a radius of curvature less than a threshold value, such as one or more threshold values of less than 2 mm, less than 3 mm, and less than 5 mm.

[0094] For example, method 5000 further includes operating the tow cutter assembly 2300 at positions 7001-C, 7002-C, 7003-C along paths 7001, 7002, 7003, 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 linear foot segment 1110, in front of the end point of the path.

[0095] For example, method 5000 further includes unwinding the tow 100, which includes rotating the pressure foot device 1100 5310.

[0096] For example, method 5000 includes measuring 5350 the distance 205 between the linear foot segment 1110 and the target surface 200. For example, this distance corresponds to the height along the Z axis.

[0097] For example, method 5000 includes adjusting distance 205 between linear foot segment 1110 and target surface 200. For example, the adjustment of distance 205 is a function of one or more measurements of the distance from target surface 200, obtained by, for example, one or more of distance measurement detector assemblies 2600. For example, method 5000 includes adjusting distance 206 between dispenser nozzle 2940 and target surface 200. For example, the adjustment of distance 206 is a function of one or more measurements of the distance from target surface 200, obtained by, for example, one or more of distance measurement detector assemblies 2600. For example, method 5000 includes adjusting offset 2980 of the distance of dispenser nozzle 2940 relative to target surface 200, for example along the Z axis, as a function of distance 205 between linear foot segment 1110 and target surface 200.

[0098] For example, method 5000 includes translating fiber tow 100 within groove 1130 by length 110 included in the range from 2 mm to 30 mm, and guiding pressure foot device 1100 along landing trajectories 8010, 8020, 8030 onto target surface 200.

[0099] For example, method 5000 includes forming one or more bend portions along the length of fiber tow 100 by passing fiber tape 90 through one or more grooves having a rectangular cross-section. For example, passing includes engaging and disengaging fiber tape 90 with the interior of one or more grooves, for example, fixed grooves, for example, the grooves of one or more grooved wheels. For example, passing results in one or more of aligning tape 90, pressing tape 90, and bending tape 90, for example, into tow 100.

[0100] For example, forming one or more bending portions 5110 includes passing the fiber tape 90 through one or more grooves 3522G, 3531AG, 3531BG included on one or more grooved wheels 3522, 3531A, 3531B.

[0101] For example, method 5000 includes obtaining 5120 a measurement of the longitudinal tension of the fiber tow 100 from the tow longitudinal tension detector 2710.

[0102] For example, method 5000 includes adjusting 5130 the speed of the translation 5100 of the tow 100 as a function of the measurement of the longitudinal tension of the fiber tow 100 from the tow longitudinal tension detector 2710.

[0103] FIG. 13 shows a block diagram of instructions 6000 for a method included in a computer-readable non-volatile storage device 4120. For example, the instructions 6000 or portions thereof represent a method, such as a method implemented on a computer. For example, the computer-readable non-volatile storage device 4120 includes executable instructions 6000. When these instructions 6000 are executed by one or more processors 4110 of the system 2000 to attach the elongated fiber tow 100 onto the target surface 200, the system 2000 is caused to at least a) instruct 6100 one or more of the position and speed of the first tow drawing motor 2550 to cause the elongated fiber tow 100 to be translated parallel along the groove 1130 of the pressure foot device, and b) instruct 6310 one or more of the position and speed of the second motor 1350 coupled to the pressure foot device 1100 to cause the pressure foot device to rotate. The pressure foot device 1100 includes a foot surface 1150 for pressing the fiber tow 100 onto the target surface 200. The foot surface 1150 includes a linear foot segment 1110 for pressing the fiber tow 100 onto the target surface 200. The linear foot segment 1110 includes a rear end portion 1112 and a front end portion 1111 that define a forward direction Fx from the rear end portion to the front end portion. The pressure foot device 1100 rotates about a rotation axis included within a central plane 1130MP of the groove along a center line 1130ML of the groove included between a left lip 1141 and a right lip 1142 of the groove and perpendicular to the linear foot segment 1110.

[0104] For example, the instructions 6000 include instructions for a method in which the speed at which the first motor 2550 is instructed 6315 is a function of the speed at which the second motor 1350 is instructed 6310.

[0105] For example, instruction 6000 further includes instructions regarding a method of instructing 6315 a third motor 2350 coupled to the cutter assembly 2300 to displace the blade 2340 from a first position to a second position in the cutter assembly. For example, instruction 6000 includes instruction 6330 for instructing a cut of the ear, for example, at the contact point 7001PT (see FIG. 14), as a function of the curvature of the ear paths 7001, 7002, 7003. For example, this cut is instructed when reaching the cut positions 7001-C, 7002-C, 7003-C so as to form a complete cut across the entire cross-section of the ear. For example, this cut is instructed so as to form a partial cut across a part of the cross-section of the ear. For example, the size of the cut across the cross-section of the ear is, for example, at the contact point 7001PT, a function of the radius of curvature of the path, for example, a linear function.

[0106] For example, instruction 6000 includes instructions regarding a method for adjusting the speed 6345 of the first motor 2550 as a function of an instruction sent to the third motor 2350.

[0107] For example, instruction 6000 includes instructions regarding a method for acquiring 6350 distance measurement data from one or more distance measurement detector assemblies 2600.

[0108] For example, instruction 6000 includes instructions regarding a method for adjusting 6355 the speed of the first motor 2550 as a function of a measurement acquired from one or more distance measurement detector assemblies 2600.

[0109] For example, instruction 6000 includes instructions regarding a method for acquiring 6120 measurement data from one or more ear longitudinal tension detectors 2710.

[0110] For example, instruction 6000 includes instructions regarding a method for adjusting 6130 the speed of the first motor 2550 as a function of a measurement acquired from one or more of one or more ear longitudinal tension detectors 2710.

[0111] For example, instruction 6000 includes instructions regarding a method for adjusting the relative speed of one or more first motors 2550, 3550 as a function of measurements obtained from one or more of one or more ear longitudinal tension detectors 2710.

[0112] For example, instruction 6000 includes instructions regarding a method for adjusting the infrared emissive 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 the infrared emissive power 6220 included adjusting the power supply in one or more of, for example, voltage, current, and duty cycle. For example, instruction 6000 includes instructions for adjusting the cooling 6250 of the ear. For example, one or more of the instructions for adjusting the infrared emissive power 6220 and the instructions for adjusting the cooling 6250 of the ear are for adjusting as a function of one or more of a measured value of ear tension, a translational speed of the ear, the speed of one or more motors 2550, 3550, 2950, the speed of one or more wheels 3522, 3531, the dimensions of a cross-section of one or more ears, the dimensions of a cross-section of one or more thermoplastic materials, the rotational speed of one or more rollers 2510-1, 2510-2, 2910-1, 2910-2, the temperature measured by one or more temperature sensors 1170, 2170, 2270, the relative amount of thermoplastic material included in the ear, for example in a cross-section of the ear, and a measured value of the ambient temperature. For example, instructions for adjusting the cooling 6250 of the ear include instructions for adjusting one or more of the flow rate of a cooling fluid, for example the flow rate of the cooling fluid flowing inside the heat exchanger housing 2200, by sending, for example, one or more instructions to one or more flow control devices, for example valves or vanes, included in one or more ports 2215.

[0113] For example, instruction 6000 includes instructions for 6400 storing one or more numerical 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 that include one or more of the position and orientation of the pressure foot device 1100.

[0114] For example, instruction 6000 includes instructions for a method for 6405 inserting one or more instructions for instructing the third motor 2350 coupled to the tow cutter assembly 2300 to the numerical 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 as one or more functions of the path length and the curvature of one or more of the paths.

[0115] For example, instruction 6000 includes instructions for a method for 6405 inserting one or more instructions for instructing to solve the tow 100, and this instruction includes an instruction to operate the second motor 1350.

[0116] FIG. 10 is a top view of a system 2000 for attaching an elongated fiber tow, provided on an X-Y gantry 3900 further including an object support 3932 operating in the Z direction. For example, the gantry 3900 includes an X motor 3910 for translating one or more of the pressure 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 gantry 3900 includes a Z motor 3930 for operating the object support 3932 in the Z direction. For example, instruction 6000 includes one or more spatial position coordinates X F , Y F , Z Fand instructions for a method 6320 for instructing one or more motors 3810, 3820, 3830, 3840, 3850, 3910, 3920, 3930 so as to configure one or more of the position and velocity of the pressure foot device 1100 in one or more spatial direction coordinates.

[0117] For example, instruction 6000 configures one or more of the position (X F Y F Z F φ F θ F ψ F ) and velocity of the pressure foot device as a function of measurements obtained from one or more distance measurement detector assemblies 2600, and includes instructions for a method 6360 for adjusting the distance 205 between the linear foot segment 1110 and the target surface 200, for example, by instructing one or more of motors 3820, 3830, 3840, 3850, 3930. For example, adjusting the distance 205 includes instructions that this distance is a function of one or more measurement data of the distance from the target surface 200, for example, data obtained from one or more of the distance measurement detector assemblies 2600.

[0118] For example, instruction 6000 includes instructions for a method 6360 for adjusting the distance 205 between the linear foot segment 1110 along the rotation axis Z and the target surface 200 to a value included in the range from 0.05 mm to 1.0 mm. For example, this value is included in the range from 0.15 mm to 0.5 mm, for example, from 0.2 mm to 0.3 mm, and for example, is 0.25 mm.

[0119] For example, instruction 6000 includes instruction 6360 regarding a method for translating and rotating the pressure foot device 1100 along paths 7001, 7002, 7003 from the start points 7001-S, 7002-S of the paths to the end points 7001-E, 7002-E of the paths. The second motor 1350 is instructed such that the linear foot segment 1110 remains on the same straight line as the local tangent 7001T of the paths 7001, 7002, 7003 of the pressure foot device 1100, and the contact point 7001PT remains within the segment extending from the front end 1111 of the linear foot segment to the length of the center line 1130ML of the groove. For example, the translation and rotation are performed simultaneously.

[0120] For example, instruction 6000 includes instruction 6370 regarding a method for adjusting the distance 206 between the nozzle 2940 and the target surface 200. For example, instruction 6370 for adjusting the distance 206 is a function of one or more of the distance 206 between the nozzle 2940 and the target surface 200, the offset of the nozzle 2940 along one or more of, for example, the X-axis, Y-axis, and Z-axis with respect to the Z-axis passing through the rotation axis of the pressure foot device 1100, the three-dimensional geometric features of the target surface, the one or more speeds of the pressure foot device 1100 and the nozzle 2940 with respect to the target surface 200, and the three-dimensional geometric features of the paths 7001, 7002, 7003 characterized, for example, by the curvature of the curved portion of the path included between two linear portions in one or more of the X-dimension, Y-dimension, and Z-dimension at the contact point 7001PT at the maximum curvature of the curved portion. For example, forming a path including a portion including one or more curves or curved portions involves reducing the distance 206 between the nozzle 2940 and the target surface 200 within the curved portion as a function of speed, for example, including a rule including a linear function of speed, compared to the distance 206 of the linear portion.

[0121] For example, instruction 6000 includes instruction 6380 for adjusting an offset of a distance, for example, along one or more of the X-axis, Y-axis, and Z-axis, between the pressure foot device 1100 and the nozzle 2940. For example, instruction 6380 for adjusting the offset of the distance is a function of the three-dimensional geometric features of paths 7001, 7002, 7003, for example, following the changes in the elevation of the path, to maintain a constant height of the nozzle 2940 relative to the target surface 200.

[0122] For example, instruction 6000 includes instruction 6390 for guiding the pressure foot device 1100 onto the target surface 200 along landing trajectories 8010, 8020. The landing trajectories include, for example, a distance or altitude 205 equal to the thickness 215 of a pressed filament or bent tow, for example, in the range of about 30 μm to about 3 mm, for example, about 50 μm to about 1 mm, for example, about 100 μm to about 400 μm, and are parallel to the target surface 200, for example, including track portion 8030. For example, the landing trajectory reaches a certain distance or altitude relative to the target surface 200 before the rotational axis Z of the foot shaft is brought onto the target surface 200. For example, the landing trajectory includes a rounded portion 8020 so as to combine, for example, a descending trajectory 8010, for example, a linearly descending trajectory, with a trajectory portion parallel to the target surface. For example, the tangent of the descending trajectory 8010, for example, the tangent before the rounded portion 8020, forms an angle with the target surface 200 that is included in the range of 0 degrees to 90 degrees, for example, 3 degrees to 60 degrees, for example, 3 degrees to 45 degrees. For example, the landing trajectory is indicated by a distance meter 2650 disposed in front of the pressure foot device 1100. For example, the landing trajectory starts from an initial approach height 216 included in the range of 100 mm to 30 μm, for example, 50 mm to 30 μm relative to the target surface. For example, instruction 6390 for guiding the pressure foot device along the landing trajectory includes instructions for resolving, beyond the foot surface 1150 of the pressure foot device, for example, an initial tow length 110 for tethering the tow to the surface. For example, the initial tow length 110 has a range of 0.5 mm to 50 mm, for example, 1 mm to 30 mm, for example, 2 mm to 25 mm, for example, 10 mm to 20 mm.

[0123] For example, instruction 6000 includes one or more spatial position coordinates (X F , Y F , Z F ) and one or more spatial direction coordinates (φ F , θ F , ψ FInstructions 6420 for instructing one or more motors 3810, 3820, 3830, 3840, 3850, 3910, 3920, 3930, 2930 are included to configure one or more of the position and speed of the dispenser nozzle 2940 in .

[0124] For example, instruction 6000 includes instructions 6430 for instructing the dispenser nozzle extension actuator 2930 to adjust one or more of the extended position 2980 and speed of the dispenser nozzle as a function of one or more of the position 205 and speed of the pressure foot device 1100. For example, instruction 6000, for example instruction 6430, includes instructions for adjusting the speed of one or more retraction motors, for example the retraction motor 2950 of the dispenser nozzle, to draw in a thermoplastic material, for example. This speed is adjusted as a function of one or more of the speed of the tow retraction motor, the curvature of the bend in the path, and the distance 206 between the nozzle 2940 and the target surface 200.

[0125] While the foregoing matters apply to each embodiment of the present disclosure, other additional embodiments of the present invention may be devised without departing from the basic scope of the present invention. Accordingly, the scope of the present disclosure is determined by the appended claims.

[0126] In the context of describing the disclosed embodiments (particularly in the context of the appended claims), the terms "a", "an", and "the", as well as the use of similar designators, shall be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by the context. The terms "comprising", "having", "including", and "containing" shall be construed as open-ended terms (i.e., meaning "including, but not limited to") unless otherwise indicated. The term "connected" shall be construed to mean that something is either partially or wholly internally incorporated, attached, or joined together, even if there is something intervening. The recitation of a range of values herein is merely intended to serve as a shorthand method of referring individually to each separate value within the range, unless otherwise indicated herein and each separate value is incorporated herein as if it were individually recited herein. All of the methods described herein can be performed in any suitable order, unless otherwise indicated herein or otherwise clearly contradicted by the context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein is merely intended to clarify the embodiments of the invention and does not limit the scope of the invention unless otherwise claimed. The language of the specification should not be construed to indicate any non-claimed element as essential to the practice of the invention.

[0127] Preferred embodiments of the present disclosure are included and described herein as the best mode known to the inventors for carrying out the present application. Variations of these preferred embodiments will become apparent, for example, by reading the foregoing description. The inventors expect those skilled in the art to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, the present invention includes all variations and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Further, any combination of the above-described elements in all possible variations thereof are included by the present invention unless otherwise indicated herein or otherwise clearly contradicted by context.

[0128] All references, including publications, patent applications, and patents listed herein are 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 pressure foot device (1100) for attaching an elongated fiber tow (100) onto a target surface (200), wherein the pressure foot device (1100) comprises: A foot surface (1150) comprising a linear foot segment (1110) configured to press the fiber tow (100) onto the target surface (200); The linear foot segment (1110) having a rear end portion (1112) and a front end portion (1111), the rear end portion (1112) and the front end portion (1111) defining a front direction (Fx) from the rear end portion to the front end portion; The foot surface (1150); A groove (1130) having a left lip (1141) and a right lip (1142) configured to guide the fiber tow onto the foot surface (1150); The groove (1130) defining a central plane (1130MP) of the groove as a flat portion along a center line (1130ML) of the groove, and extending between the left lip (1141) and the right lip (1142) of the groove; The groove (1130) being coupled onto the front end portion (1111) of the linear foot segment (1110) and being oriented at an elevation angle (1130A) with respect to the linear foot segment (1110); The groove (1130) having a flared end portion (1120) coupled to the foot surface (1150); The groove (1130); A hollow foot shaft (1200); and A part of the hollow foot shaft having an outer diameter and a rotation axis (Z), and being configured to form a running fit within a foot shaft housing (2100); The rotation axis being orthogonal to the linear foot segment (1110) and being included in the central plane of the groove; The pressure foot device (1100).

2. The foot surface (1150) comprises: A first toe surface (1161) on a first side of the central plane (1130MP) of the groove, and being oriented at a first elevation angle (1161A1) and a first azimuth angle (1161A2) offset from the front direction (Fx); and A second toe surface (1162) on a second side of the central plane (1130MP) of the groove, and being oriented at a second elevation angle (1162A1) and a second azimuth angle (1162A2) offset from the front direction (Fx). The device according to claim 1, wherein the first azimuth angle (1161A2) and the second azimuth angle (1162A2) are included within a range of 30 degrees to 90 degrees with respect to the front direction (Fx).

3. The device according to claim 1, wherein the flare-shaped end portion (1120) includes a chamfer portion (1125) having an elevation angle (1125A) within a range of 30 degrees to 70 degrees with respect to the front direction (Fx).

4. The device according to claim 1, wherein the device includes a hollow foot shaft (1200), and an axis of the hollow foot shaft (1200) is included on a center plane (1330MP) of the groove.

5. The device according to claim 1, wherein the device includes a foot pinion (1210), and an axis of the foot pinion (1210) is included on a center plane (1330MP) of the groove.

6. The device according to claim 1, wherein the foot surface (1150) includes a first material within a first sector (1151) proximal to the front end portion with respect to the front end portion, and a second material within a second sector (1152) distal from the front end portion, and a thermal conductivity of the second material is equal to or less than half of a thermal conductivity of the first material.

7. The device according to claim 1, wherein the foot surface (1150) includes a heat sink (1155).

8. The device according to claim 1, further comprising a foot shaft housing (2100), and a part of the hollow foot shaft forms a sliding fit within the foot shaft housing (2100).

9. The device according to claim 8, wherein the foot shaft housing (2100) includes one or more heat sources (2110).

10. Furthermore, the device includes one or more pinch roller assemblies (2500), one or more of the pinch roller assemblies (2500) include a first roller (2510-1) and a second roller (2510-2), and a tangent common to the first roller and the second roller is on the same straight line as a rotation axis (Z) of the foot shaft.

11. A method (5000) for attaching an elongated fiber tow (100) to a target surface (200), the method comprising: The step of translating the elongated fiber tow (100) through the hollow foot shaft (1200) into the groove (1130) of the pressure foot device (1100) and translating it parallelly onto the foot surface (1150) of the pressure foot device (1100) (5100), wherein the groove (1130) includes a left lip (1141) and a right lip (1142), and a groove center plane (1130MP) extending between the left lip (1141) and the right lip (1142) of the groove (1130) is defined along the center line (1130ML) of the groove, said translating step (5100), the step of guiding the fiber tow in the groove to the flared end (1120) of the groove (5200), the step of curving the fiber tow around the flared end of the groove to a linear foot segment (1110) included in the foot surface (1150) of the pressure foot device (5230), wherein the linear foot segment (1110) includes a rear end portion (1112) and a front end portion (1111), and the rear end portion (1112) and the front end portion (1111) defining a front direction (Fx) from the rear end portion to the front end portion, and the groove (1130) is coupled to the front end portion of the linear foot segment (1110) and is oriented at an elevation angle (1130A) with respect to the linear foot segment, said curving step (5230), the step of pressing the fiber tow between the linear foot segment and the target surface (200) (5240), comprising, a part of the hollow foot shaft has an outer diameter and a rotation axis (Z), and is configured to form a running fit within a foot shaft housing (2100), the rotation axis is orthogonal to the linear foot segment (1110) and is included in the center plane of the groove, said method.

12. The method according to claim 11, wherein one or more of the step of translating (5100), the step of guiding (5200), the step of curving (5230), and the step of pressing (5240) includes heating the fiber tow (100) (5210).

13. The method according to claim 11, wherein the step of pressing (5240) includes cooling the fiber tow (100) (5250).

14. The method according to claim 11, further comprising rotating (5310) the pressure foot device (1100) about a rotation axis (Z) that is perpendicular to the linear foot segment (1110) and is included in the central plane (1130MP) of the groove.

15. The method according to claim 11, further comprising one or more of translating (5320) and rotating (5310) the pressure foot device (1100) along a path (7001, 7002, 7003) from a start point (7001 - S) to an end point (7001 - E) of the path, wherein the linear foot segment (1110) is on the same straight line as a tangent (7001T) of the path of the pressure foot device (1100), and a contact point (7001PT) with respect to the path (7001) is included within the central plane (1130MP) of the groove.

16. The method according to claim 15, wherein the fiber tow (100) is translated within the groove (1130) at a speed equal to the speed at which the contact point (7001PT) with the path (7001) translates along the path.

17. The method according to claim 15, further comprising operating (5340) the tow cutter assembly (2300) at a position (7001 - C, 7002 - C, 7003 - C) along the path (7001, 7002, 7003) in front of 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 linear foot segment (1110).

18. The method according to claim 15, further comprising untwisting (3545) the fiber tow (100), the untwisting step including rotating (5310) the pressure foot device (1100).

19. The method according to claim 11, further comprising measuring (5350) the distance (205) between the linear foot segment (1110) and the target surface (200).

Images