An ultrasonic device for compression molding that enables the coordinated operation and motion of multiple ultrasonic compression molding horns.

The continuous filament lamination machine with independently movable ultrasonic horns addresses scalability and interlaminar strength issues by using ultrasonic compaction to fuse and compact matrix materials, enhancing manufacturing flexibility and reducing porosity.

JP7863610B2Active Publication Date: 2026-05-21NORTHROP GRUMMAN SYSTEMS CORP
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Patent Information

Authority / Receiving Office
JP · JP
Patent Type
Patents
Current Assignee / Owner
NORTHROP GRUMMAN SYSTEMS CORP
Filing Date
2022-03-28
Publication Date
2026-05-21

AI Technical Summary

Technical Problem

Existing additive manufacturing machines face challenges in scalability, affordability, and flexibility due to gantry-type methods, and laminated continuous filament composite structures lack sufficient interlaminar strength without dense fusion of adjacent layers, leading to voids and cold bonds.

Method used

A continuous filament lamination machine with independently movable ultrasonic horns for compression molding, combining ultrasonic, mechanical, and thermal energies to fuse and compact matrix materials, improving interlayer strength and reducing porosity.

Benefits of technology

Enhances manufacturing flexibility, reduces part porosity, and improves interlayer strength and surface smoothness by ensuring complete fusion of layers using ultrasonic compaction.

✦ Generated by Eureka AI based on patent content.

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Abstract

A continuous filament deposition model manufacturing machine for fabricating a part by laying down a continuous monofilament or continuous synthetic filament material layer by layer on a tool or substrate. The machine includes a system operable to move in at least three degrees of freedom and a placement module coupled to the system configured to deposit the continuous filament material. The placement module includes a guide for guiding the material to the part and an ultrasonic compression molding device (160) for compression molding the material as it is deposited from the placement module. The compression molding device includes an ultrasonic driver, a mounting member, and a plurality of ultrasonic horns (166) independently coupled to the mounting member and independently movable from one another. The plurality of ultrasonic horns are ultrasonically vibrated to melt or flow the material and to fuse and compression mold the material to the tool or substrate.
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