Hybrid textile structure machine

Abstract

A yarn carrier module (YCM) (100) includes: a motion platform (101) including a plurality of permanent magnets configured to generate a magnetic field in the presence of an external electromagnet; a yarn spool (102) attached to the motion platform (191) onto which a yarn (103) may be wound: a tensioning device (104) operatively connected to the yarn spool (102); a tension sensor (105) capable of measuring tension on the yarn (103); a YCM controller (106) configured to adjust said tension; a wireless communication module (107); and a battery (108). A hybrid textile structure machine (HTSM) (10) includes at least one YCM (100), at least one modular planar motion stage (200), and a central controller (300) configured to provide individual motion commands to the at least one YCM (100). The at least one YCM (100) is movable over the at least one modular planar motion stage (200) without predefined tracks.

Description

HYBRID TEXTILE STRUCTURE MACHINEFIELD OF THE DISCLOSURE

[0001] The present disclosure relates to a textile manufacturing machine, and in particular to a machine capable of integrating multiple textile structures into a seamless textile in a single manufacturing process.BACKGROUND OF THE DISCLOSURE

[0002] Textiles are a fundamental innovation that enable simple and complex product developments. Primary classifications of textile structures include weaving, warp knitting, weft knitting, twisting, and braiding. Each class of structures require specialized equipment to generate functional textiles targeted at a specific need; however, each machine can only generate fabrics within its class.

[0003] Advanced processing techniques such as j acquard knitting or j acquard weaving have revolutionized the textile world by offering granular programmatic control of the textile pattern and design, which allows for tuned zonal changes in textile structure. Further advancements have introduced new performance attributes to each class. For example, weft insertion can be integrated into a knitted structure to introduce directional tensile performance and a modified aesthetic. These technical innovations enable new performance benefits but are incremental in their approach. Examples of this are braiding as compared to lace braiding or 3D braiding, and as weaving compared to leno weaving. These added features typically increase equipment costs, decrease production speed, and increase design complexity.

[0004] It would be desirable to tune textile performance beyond what is possible working within these separate classes. Providing a method of manufacturing textiles that blends classes and opens up new performance qualities and structures would open new opportunities in many fields, such as medical, composites, safety, sports goods, embedded electronic textiles, wiring harnesses, robotics, actuators, tensile structures, apparel, and footwear.

[0005] These and other shortcomings are addressed by aspects of the present disclosure.SUMMARY

[0006] The present disclosure addresses the need for a versatile textile manufacturing system by integrating multiple textile structures, such as weaving, knitting, and braiding, into a single machine. This integration allows for the creation of complex, hybrid textile structures with improved material properties and design possibilities.

[0007] Specific aspects of the disclosure relate to a yam carrier module (Y CM) ( 100) including: a motion platform (101) including a plurality of permanent magnets configured to generate a magnetic field in the presence of an external electromagnet; a yam spool (102) attached to the motion platform (101) onto which a yam (103) may be wound; a tensioning device (104) operatively connected to the yam spool (102); a tension sensor (105) capable of measuring tension on the yam (103); a YCM controller (106); a wireless communication module (107); and a battery (108). The YCM controller (106) is configured to receive data from the tension sensor (105) and operate the tensioning device (104) to adjust the tension on the yam (103). The wireless communication module (107) is configured to receive control commands for the YCM controller (106).

[0008] Further aspects of the disclosure relate to a hybrid textile structure machine (HTSM) (10), including: a. at least one YCM (100) as described above; b. at least one modular planar motion stage (200) including an array of stage electromagnets configured to engage with the permanent magnets on the at least one YCM (100) and cause the at least one YCM (100) to levitate on the at least one modular planar motion stage (200); and c. a central controller (300) configured to operate the array of stage electromagnets and provide individual motion commands to the at least one YCM controller. The at least one YCM (100) is movable over the at least one modular planar motion stage (200) without predefined tracks.BRIEF DESCRIPTION OF THE FIGURES

[0009] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by w ay of limitation, various aspects discussed in the present document.

[0010] FIGS. 1A and IB show' a top perspective view and side view, respectively, of a yam carrier module according to aspects of the disclosure.

[0011] FIG. 2 shows how a take-up mechanism can shift the convergence zone (400) and how YCM motion and convergent zone location can impact the functional distance (401) of the yam from the Y CM.

[0012] FIGS. 3A-C show a top view of modular planar motion stages (200) configured to create stages with various configurations so the YCMs (100) can travel over the surface.

[0013] FIG. 4 shows a top view of the YCM (100) moving freely over the X-Y plane in multiple vectors simultaneously.

[0014] FIG. 5 shows a side view of several YCM (100) illustrating z-axis lift, rotational motion, and axial tipping.

[0015] FIG. 6 shows two modular planar motion stages (200) including a gap (201) through which stationary' longitudinal yams can pass to each convergence zone.

[0016] FIG. 7 shows core materials being fed through a modular planar motion stage (200) to the take-up.

[0017] FIG. 8 shows a mandrel passing through a modular planar motion stage (200).

[0018] FIG. 9 shows three potential configurations for yam take-up, including radial(402), roller (403), and robotic (404).

[0019] FIG. 10 shows how the movement of the take-up system (400) and a consolidation ring (405) can influence convergence of the yams (103).

[0020] FIG. 11 shows how a consolidation ring (405) can travel separately from the take-up system (400) to help influence yam consolidation.

[0021] FIG. 12 shows various examples of engagement tool shapes, including hooks, needles, combs, feeders, and pincers.

[0022] FIG. 13 shows the implementation of yam manipulators as a single unit or in an array.

[0023] FIG. 14 shows a yam diverted from a direct path from the YCM to the convergence zone via an engagement tool.

[0024] FIG. 15 shows a pit stop area where YCM can be, e.g., recharged, refilled, replaced, and spliced.

[0025] FIG. 16 shows an example of how visual programming could simplify the complexify of programming the motion required to build functional textiles.

[0026] FIG. 17 shows yam-twisting (left) and yam covering (right) structures that can be achieved using multiple YCMs.

[0027] FIG. 18A shows the Y CM motion to achieve S twists in a single yam.

[0028] FIG. 18B shows the Y CM motion to achieve Z twists in a single yam.

[0029] FIG. 19 shows the Y CM motion for a twisted pair.

[0030] FIG. 20 shows the YCM motion for a covered yam.

[0031] FIG. 21 shows the YCM motion for a covered yam by a twisted pair.

[0032] FIG. 22 shows an example of how twisted yam groups can bifurcate and twist independently with different amounts of twists per inch.

[0033] FIG. 23 shows a twisted yam assembly that intertwines two sets of yam pairs and changes the twist direction after entanglement.

[0034] FIG. 24 shows a twisted pair that changes twists per inch dynamically during take-up.

[0035] FIG. 25 shows one yam exiting a 4-yam twisted structure and then re-entering at a later point.

[0036] FIG. 26 shows the convergence zone as many yams become a circular braided structure.

[0037] FIG. 27 shows a flat braid structure.

[0038] FIG. 28A shows an example of a square braid structure.

[0039] FIG. 28B shows the carrier path that could be taken to form a rectilinear braid.

[0040] FIG. 29 shows how multi-furcation could be used to create a strut structure.

[0041] FIG. 30 shows a braid that bifurcates into two independent braid structures.

[0042] FIGS 31 A and 3 IB show “lace braided” structures with different densities.

[0043] FIGS. 32A and 32B show examples of braided structures having different braid angles.

[0044] FIG. 33 shows a braided structure where yam elements exit the structure and re-enter at a later point.

[0045] FIGS. 34A and 34B show examples of structures where yams are passed between two structural features to created conjoined structures including a ladder twist (FIG. 34A) and a tubular spacer braid (FIG. 34B).

[0046] FIG. 35 shows an example of a woven fabric with 0 / 90 yam bias.

[0047] FIG. 36 shows examples of the YCM motion required to create woven structures on the HTSM.

[0048] FIG. 37 show s the motion of the YCM that could create a tubular w oven structure.

[0049] FIG. 38 shows a region where yam “floats” above the warp yams.

[0050] FIG. 39 shows the YCM motion for woven materials that transition yams from warp to weft.

[0051] FIG. 40 shows the resulting textile structure for a woven fabric that transitions warp direction yams into weft yams.

[0052] FIG. 41 shows an example of a leno woven structure that uses twisted warp yams to create space between weft yams.

[0053] FIG. 42 shows how the HTSM can change twisted pairs dynamically in a textile, creating new fabric structures.

[0054] FIG. 43 shows an example of a weft knitted-like structure created with each course of yam on an independent YCM.

[0055] FIG. 44 shows a YCM interacting with a bed of needles engagement tools to make weft-knit structures.

[0056] FIG. 45 shows two yams interacting with a needle engagement tool and a sinker engagement tool to create warp-knit chains.

[0057] FIG. 46 shows an example of a net structure created by knotting yams.

[0058] FIG. 47 shows how an engagement tool can lower a yam to the bed so a YCM can pass over without entangling the Y CM.

[0059] FIG. 48 shows two motion stages on different planes utilizing a single take-up system.

[0060] FIG. 49 shows a plurality of YCMs, each YCM having a unique identifier.

[0061] FIG. 50 shows an empty and a full yam spool on a YCM, with the weight measured by a magnetic resonance system.

[0062] FIG. 51 shows how take-up speed can be manipulated to change the convergence angle by elevating the convergence zone.

[0063] FIG. 52 shows a braided structure transitioning to a coiled structure.

[0064] FIG. 53 shows a wo ven-like structure where weft and warp warns twist to control porosity'.

[0065] FIG. 54 shows a braided structure with a perforation that has a finished edge.

[0066] FIG. 55 shows a knitted structure transitioning to a woven structure.

[0067] FIGS. 56 and 57 show examples of modular planar motion stage areas.

[0068] FIG. 58 shows a variety of shapes in which modular stages could be created for custom stage geometry.

[0069] FIG. 59 shows modular stages with a gap that can be traversed by the YCM.

[0070] FIGS. 60A and 60B show an engagement tool being used as a control implement from below the consolidation zone to force textile structures towards the consolidation area.

[0071] FIG. 61 is an example of a prototype used to form complex textile structures according to aspects of the disclosure.

[0072] FIGS. 62A-62D show examples of textile structures formed using the prototype of FIG. 61.DETAILED DESCRIPTION

[0073] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term “comprising” can include the aspects “consisting of’ and “consisting essentially of.” Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

[0074] As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a yam carrying module” includes a two or more yam carrying modules.

[0075] Ranges can be expressed herein as from one value (first value) to another value (second value). When such a range is expressed, the range includes in some aspects one or both of the first value and the second value. Similarly, when values are expressed as approximations, by use of the antecedent ‘about,’ it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0076] As used herein, the terms “about” and “at or about” mean that the amount or value in question can be the designated value, approximately the designated value, or aboutthe same as the designated value. It is generally understood, as used herein, that it is the nominal value indicated ± 10% variation unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such. It is understood that where “about” is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

[0077] Various combinations of elements of this disclosure are encompassed by this disclosure, e.g., combinations of elements from dependent claims that depend upon the same independent claim.

[0078] Moreover, it is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherw ise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

[0079] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and / or materials in connection with which the publications are cited.Yarn Carrier Module (YCM)

[0080] With reference to FIGS. 1 A and IB, aspects of the disclosure relate to a yam carrier module (YCM) (100) including: a motion platform (101) including a plurality of permanent magnets configured to generate a magnetic field in the presence of an external electromagnet; a yam spool (102) attached to the motion platform (101) onto which ayam (103) may be wound; a tensioning device (104) operatively connected to the yam spool (102); a tension sensor (105) capable of measuring tension on the yam (103); a YCM controller (106); a wireless communication module (107); and a battery (108). The YCMcontroller (106) is configured to receive data from the tension sensor (105) and operate the tensioning device (104) to adjust the tension on the yam (103), and the wireless communication module (107) is configured to receive control commands for the YCM controller (106).

[0081] The yam carrier module (YCM) (100) supports the motion and tension of the yam spool. YCMs are versatile and can handle different yam types and materials, such as — but not limited to — monofilament, multifilament, wires, and ribbons. In some aspects, the YCM can be configured with different feed mechanisms and eyelets (109) to support tensile members with different stiffnesses and sectional dimensions. In further aspects the YCM can be modified to support multiple yams, or bulk loads by changing the configuration or the platform.

[0082] The tensioning device (104) controls the tension on the yam spool (102) on the YCM. In one aspect the tensioning device (104) is a motor. In other aspects, the tensioning device (104) includes a spring, pulley, or a friction mechanism.

[0083] Tension control is an important factor in the resulting textile stmctures and may be adjusted to accommodate changes in the distance (401) of the yam path from the YCM to the convergence zone (400). See FIG. 2. As further discussed herein, this variance can be caused by a change in the convergence zone height, or by a change of the hypotenuse length by changing the position of the YCM.

[0084] In some aspects, tension control can be used to tune the machine’s performance based on the yam materials selected and their mechanical properties. In further aspects, tension control can be used to change the relational tension between two yams, allowing for control over how yam structures are shaped as they converge and form a textile. This approach can be used to ensure yams are forced into the appropriate configurations in the textile and give control of the density of the resulting textile structure.

[0085] The YCM (100) is capable of adjusting tension in real time, allowing the user to control and adjust the relative tensions over the length of a textile’s creation. This is relevant when considering a transition between textile structures that require different levels of tension. For example, weaving requires much higher tensions, specifically in the length of the textile, than knitting. This can also help control textile loop feature size, textile density, or porosity.

[0086] As noted, in some aspects the YCM (100) includes the tensioning device (104), a YCM controller (106), a wireless communications module (107), a battery (108), and a tension sensor (105).

[0087] In further aspects, the tension sensor (105) may be replaced with one or more other sensors, including but not limited to a strain gauge sensor, load cell sensor, pressure sensor, torque sensor, piezo sensor, or a force sensor. In a specific aspect tension may be detected by estimating the torque of the tensioning device through current or voltage sensing. These alternative sensing methods could be used independently or in parallel, and could provide a closed-loop tensioning system.

[0088] The wireless communications module (107) communicates with the YCM controller and an external controller (discussed below) to send and receive data for real time tension modifications to the YCM (100).

[0089] In some aspects the battery (108) is removable so that it can be swapped automatically or manually. The battery (108) could also be rechargeable without removing it from the YCM (100), as discussed further herein.

[0090] Aspects of the disclosure further include an eyelet (109) for guiding the yam (103). Guiding includes receiving, expelling and reloading the yam.

[0091] One or more of the components described herein may be removable from the YCM, including the yam spool (102). tensioning device (104), tension sensor (105), YCM controller (106), wireless communication module (107), and battery (108) is removable from the YCM (100).

[0092] In certain aspects the YCM controller (106) is configured to monitor yam consumption over time and estimate yam (103) remaining on the yam spool (102). In further aspects, the estimate is based on one or more of (1) historical feed rates, (2) a simulation of expected usage, or (3) measurement of an effective magnetic force required to levitate the YCM in response to the external electromagnet, wherein the measurement of effective magnetic force required to levitate the YCM changes in response to an amount of yam remaining on the spool.

[0093] In some aspects the YCM further includes an actuator to alter a position or height of the eyelet (109). The actuator could enhance the functionality of the YCM or engagement tools attached thereto.Hybrid Textile Structure Machine (HTSM)

[0094] With reference to FIGS. 2-7, further aspects of the disclosure include a hybrid textile structure machine (HTSM) (10), including: (a) at least one YCM (100) as described herein; (b) at least one modular planar motion stage (200) including an array of stage electromagnets configured to engage with the permanent magnets on the at least one YCM (100) and cause the at least one YCM (100) to levitate on the at least one modular planarmotion stage (200); and (3) a central controller (300) configured to operate the array of stage electromagnets and provide individual motion commands to the at least one YCM controller. The at least one YCM (100) is movable over the at least one modular planar motion stage (200) without predefined tracks.

[0095] In certain aspects the HTSM comprises a plurality of YCMs (100), and the central controller (300) provides instructions to the stage electromagnets and YCM controller (106) on each of the plurality of YCMs (100) to control the motion of the plurality of YCMs (100) and the yam tension on the yam (103) of each of the plurality of YCMs (100) to produce a textile structure.

[0096] In further aspects each of the plurality of YCMs (100) move over the at least one modular planar motion stage (200) on a programmed path. The programmed path is adaptable in real time based on motion or performance variations detected by the central controller (300) or plurality ofYCM controllers (106).

[0097] The HTSM is designed to allow a wide array of textile structures to be formed by integrating and surpassing the capabilities of traditional textile machinery. The HTSM facilitates the production of innovative textiles that combine vanous fabric structures, such as weaving, knitting, and braiding, into a single, seamless textile, enhancing the products’ functional and aesthetic qualities. In particular aspects the textile structure comprises a woven structure, a braided structure, a knitted structure, a twisted structure, or a hybrid structure comprising a combination thereof.

[0098] The HTSM can build textiles from various flexible tensile materials, including yam, twine, string, thread, rope, ribbon, wire, cord, webbing, film, tape, and filament. These materials can comprise natural fibers, synthetic fibers, composite filaments, metals, polymers, or any materials that can be wound on a spool. The freedom of materials types makes it suitable for diverse applications across industries such as medical textiles, automotive composites, performance garments, and other technical textile applications.

[0099] The modular planar motion stage (200) may be customized and scaled to fit the needs of the specific textile application (FIGS. 3A-3C). This stage supports the free movement of YCMs linearly across multiple axes — X, Y. Z, and rotational axes — as shown in FIGS. 4 and 5. The modularity allows for quick reconfiguration to adapt to different production requirements. Modular planar motion stages (200) can come in a variety of shapes based on application requirements. See FIG. 58.

[0100] The modular planar motion stage (200) may be mounted so that they register closely with adjacent modular planar motion stages. In some aspects, the modular planarmotion stage(s) can be mounted with a physical gap (201) between them, as shown in FIG. 6. This can allow other objects to be mounted and / or pass through in the gap (FIG. 6). Alternatively, the modular planar motion stage (200) includes an opening to allow one or more objects — such as but not limited to a core or a mandrel — to pass through the modular planar motion stage (200). See FIGS. 7 and 8. Small gaps between modules do not hinder the motion of the YCM platform; as shown in FIG. 59 the YCM may pass over the gap.

[0101] With reference to FIGS. 9-11, in further aspects the HTSM includes a dynamic take-up system (400) configured to adjust (1) a position of a yam convergence zone relative to the modular planar motion stage (200) or (2) movement of a fabric structure formed by the HTSM.

[0102] In certain aspects the position of the yam convergence zone relative to the at least one modular planar motion stage (200) is adjustable in three directions including an X- direction and Y-direction corresponding to a length and width of the at least one modular planar motion stage (200) and a Z-direction corresponding to a height from the at least one modular planar motion stage (200).

[0103] The take-up system advances the textile as it is being formed, controlling factors like fabric density and fiber angle. As shown in FIG. 9, the take-up system (400) may include a radial take-up reel (402), tensioned rollers (403), or a robotic arm (404). Take-up systems (400) can also move their position in relation to the modular planar motion stage (200), helping to control take-up speeds and influence textile structure. See FIG. 10. A consolidation ring (405) may also be used to control the yam’s take-up position and convergence zone. The consolidation ring can move in tandem or independently of the takeup reel. See FIG. 11.

[0104] In some aspects the HTSM includes one or more engagement tools configured to perform at least one of the following activities: manipulate a position of the yam or a plurality of yams; knot the yam or a plurality of yams; cut the yam or a plurality of yams; fuse the yam or a plurality of yams; introduce a new' yam or plurality of yams into the textile; remove one or more yams from the textile; or assist with convergence zone formation. Examples of engagement tools are shown in FIGS. 12 and 13.

[0105] In certain aspects the one or more engagement tools are mounted on the at least one modular planar motion stage (200), one or more of the YCMs (100), or on a platform that is separate from the at least one modular planar motion stage (200).

[0106] The engagement tools can be mounted in various positions on, above, or near the modular stage, or attached to YCMs or other motion elements. The role of theengagement tool(s) is to manipulate yam paths, manipulate consolidation, terminate yams, introduce yams, and enable more complex textile structures. Engagement tools can consist of one or more manipulators that engage with yam(s) on the stage. Engagement tools can be static or dynamic, using the at least one modular planar motion stage (200), YCMs (100), independent platforms or external motion systems to interact with yams. Manipulators have various geometries , including hooks, needles, combs, fingers, rods, cones or pincers, and can be used as single entities (see FIG. 12), assemblies, or arrays (see FIG. 13). Manipulators can also be active devices such as blades, scissors, ultrasonic welder, yam heaters, or entanglement device. Manipulation of the yams can be driven by the motion of the engagement tool, the motion of the YCM (100) or a combination of both methods. This motion can be in any linear or rotary axis and could leverage the tilting capabilities of the motion platform or through motors, linear actuators, solenoids, or other conventional methods.

[0107] In one aspect the engagement tool may change the path of the yam from a 2- point linear path to a multipoint path that enables even more complex textile structures or specialized interlocking features like knotting, which can be used as textile features or as terminations. See FIG. 14.

[0108] The engagement tool may also be used integrated into the YCM existing yam path. These integrated engagement tools could influence the yam path tension or travel path. One implementation would be controlling the motions of the eyelet (109) of the YCM (100) by changing its height or location relative to the motion platform.

[0109] In some aspects the engagement tool is used as a “control implement’’ from below' the consolidation zone to force textile structures towards the consolidation areas. This device could be controlled from one or more sides of the stage, through the stage, or be mounted to a platform or YCM. See FIGS. 60A and 60B.

[0110] In further aspects an engagement tool may be used to help introduce or terminate yams to the textile structure. This could be done by connecting anon-included yam to an included yam, and then using the included yam to introduce the new yam into the textile structure. An engagement tool such as a cutting tool could also be used to trim yams and exclude them from the textile structure as it advances.

[0111] As discussed, the HTSM (10) includes a central controller (300) configured to operate the array of stage electromagnets in the at least one modular planar motion stage (200) and provide individual motion commands to the at least one YCM controller (106) on the YCM (100).

[0112] In some aspects, each moving part of the HTSM — including the YCM, takeup system (400), and engagement tool(s) — includes a control system. These control systems will typically operate independently and in a closed loop. The central controller (300) operates to synchronize each of these subsystems to operate together based on the user- created program. The central controller (300) may send positional control messages to each subsystem and receive feedback data from each system. The central controller (300) is compatible with the hardware, firmware, and software systems of each subsystem and may be capable of tw o-w ay communication through wired or wireless methods.

[0113] As noted, in some aspects the battery' (108) of the YCM (100) may be rechargeable. In certain aspects the battery' (108) may be charged while mounted to the YCM inductively through the at least one modular planar motion stage (200). inductively through a separate inductive charging stage, or through more conventional contacts such as, but not limited to, spring contacts, pogo pins, barrel jacks, or plug connections. In specific aspects the battery (108) is recharged by inductive coupling, electrical contact, or magnetic forces provided to the modular planar motion stage (200).

[0114] Accordingly, in certain aspects the HTSM includes a charging zone (202) including a system for recharging the battery (108) on one or more of the YCMs. See FIG. 15.

[0115] In some aspects the HTSM utilizes s a planar magnetic levitation system to provide unconstrained, contactless motion for a plurality of yam carrier modules (YCMs). Unlike traditional textile systems or other magnetic carrier platforms that rely on predefined control volumes or grid-constrained motion logic, the present system utilizes a continuous magnetic actuation platform enabling freeform motion across a planar or modular surface.

[0116] The at least one modular planar motion stage (200) includes in some aspects a stator array of electromagnets configured to dynamically generate a magnetic field that levitates and translates each YCM in up to six degrees of freedom. YCMs may' move independently or cooperatively, and their trajectories are not limited to any discrete lattice, track, or volume-based zone. Instead, the path of each Y CM may be defined by continuous interpolation of position vectors, based on real-time motion planning, environmental feedback, and structural formation logic. This system has several key advantages.

[0117] In certain aspects each YCM floats above the stator surface via magnetic repulsion or attraction fields. There is no mechanical contact, allowing smooth, low-friction movement and reducing material wear. Additionally’, YCMs are not confined to any physicalgrid or segmented control volumes. Paths can include curves, arcs, or compound trajectories across continuous space.

[0118] In further aspects each YCM receives individual motion commands from the central controller (300), enabling real-time adjustment of speed, position, and trajectory based on fabrication logic, yam tension data, or obstacle avoidance.

[0119] The magnetic platform supports coordination between motion and structure logic, enabling spatial separation of zones performing braiding, knitting, weaving, or twisting operations — all within a single fabrication cycle. This motion architecture provides a clear advancement beyond conventional control volume-based magnetic platforms by enabling levitated motion that is not constrained to predefined electromagnetic zones or surface topologies. The HTSM supports a new class of textile machine behavior characterized by hybrid structure formation, intelligent material handling, and dynamic zone orchestration.

[0120] The modular HTSM configuration allows expansion to any size and configurations that operate on one or multiple planar surface arrays that form a motion stage. See FIG. 48. Motion stages can be continuous or can have interruptions and can be customized to utilize the modular components efficiently based on the needs of the textile application.

[0121] The central controller (300) and other controllers — including but not necessarily limited to the YCM controller (106) and controller(s) in the take-up system (400) and on engagement tool(s) — may be programmed to provide appropriate instructions to their respective components according to conventional methods.

[0122] In certain aspects the central controller (300) is programmed to with defined routing rules that allow- carriers to avoid collisions and dynamically re-route betw een active structure zones and pit-stop stations while maintaining intended textile structures.

[0123] Although programming complex textile structures can be challenging, the HTSM (10) described herein helps provide accurate and repeatable results. One method of simplifying defined structures is visual programming to establish textile structure blocks with defined inputs and outputs. See FIG. 16. which shows an example visual program that incorporates woven features, leno features and warp-weft shift. This software system would allow- programming in planar, circular, and 3D modalities to ensure structure flexibility. The softw are could also include visualization and simulation of the resulting textile structures.

[0124] The HTSM described herein allows for creation of complex textile structures tuned to the needs of many applications. Examples are further described herein.

[0125] Numerous yam and textile structures can be formed using only a take-up system (400) and multiple YCMs (100) on the at least one modular planar motion stage (200). The full motion control of each YCM (100) allows for structures that integrate attributes of yam twisting and braiding but offer capabilities that are either complex or impossible with conventional machines. This approach can dynamically change the structure type over the length of the textile, creating structures with openings, bifurcations, struts, and textile features that are difficult or impossible with other textile methods. Combining and transitioning between the structures to accommodate unique performance requirements separates the functionality of this machine from traditional textile manufacturing.

[0126] In certain aspects the HTSM can create twisted yam structures (FIG. 17). For example, each YCM can spin to provide an S (FIG. 18 A) or Z (FIG. 18B) twist to the yam or yams coming out of a single YCM.

[0127] In further aspects two or more Y CMs can rotate together to introduce a multiyam twist (FIG. 19). A YCM or group of YCMs can transfer around the outside of a single or group of core yams to create a covered yam (FIG. 20). The machine can also combine motions to create twisted covered yams in one operation (FIG. 21).

[0128] In particular aspects which cannot be achieved by conventional machines, the HTSM can create new twisted structures that change over the textile length. For example, it can create twisted yams with bifurcation (FIG. 22) or polycation and twist direction changes without becoming unbalanced. Yam twist parameters can also change throughout a more complicated textile structure, changing rotation direction (FIG. 23), number of turns per inch (FIG. 24), or yams can be made to enter and exit the structure (FIG. 25). In yet further aspects, twisted structures can be created where twisted areas can swap yams with separate twisted areas creating cross yam cross overs.

[0129] In other aspects the HTSM can generate braided structures. YCMs may be rotationally interlaced to create circular braids (FIG. 26) or linearly to create flat braids (FIG. 27). The freedom to move anywhere on the stage also makes allows for efficient formation of solid braids (FIGS. 28A and 28B). lace braids, braided struts (FIG. 29). and bifurcated braids (FIG. 30).

[0130] In particular, bifurcated braids may be formed in some aspects by controlling the rotational paths of the YCMs (100). Additionally, by changing the relative speeds between YCMs (100) bifurcations that do not share a common braid angle are possible. In certain aspects braids with variable braid angles from yam to yam or section to section can be formed. In particular aspects — which are unique to the HTSM system described herein —YCMs need not follow repeatable or rotary paths, allowing the textile to switch constructions over time and enabling '’chain link" lace-braided structures. See FIGS. 31A and 3 IB.

[0131] In yet further aspects as shown in FIGS. 32A and 32B, the angle of the braid may be controlled by changing the location of the convergence zone. Additionally, the takeup speed can be manipulated to change the convergence angle by elevating the convergence zone. See FIG. 51.

[0132] Variable paths also allow for a transition between structures, for example from a round braid to a solid braid to a flat braid. Yams can change rotational direction, travel path, and enter or exit the body textile (see FIG. 33) without modifying the machine setup. These features can be used to create tensile textiles tuned to unique application requirements.

[0133] Additionally, braids can be created where yams are passed between independent braided features that could create flat braids with “spacer fabric’’ like features between them. A similar approach can be used with round braids to create ladder braids or tubular spacer braids. See FIGS. 34A and 34B.

[0134] Transitioning between the braided structures can create unique structures that are challenging or impossible to form using traditional mechanical braiding techniques. In one example, the HTSM can be used to form perforated braided tubes, which are accomplished by switching between round and flat braiding structures. See FIG. 54.

[0135] In some aspects woven structures may be formed from the HTSM machine by introducing a 0-degree (or any other angle) “weft” yam interlaced with multiple “warp” yams (See FIG. 35). This can be accomplished by positioning the convergence zone lower and using the motion of the interlacing yams to “beat” the weft yam (FIG. 36) into place or by using an engagement tool that helps raise and or beat the weft yam into position. See FIGS. 60A and 60B. Because the YCMs can move in any orientation, woven materials can be made flat (FIG. 36) or round (FIG. 37), and they can be fully jacquard, meaning that the weave design can be fully controlled through each yam float (700). See FIG. 38. The HTSM can also change the functionality of yams from warp to weft over the length of the textile. See FIGS. 39 and 40. The freedom of motion also allows for creating pockets, tubes, and multilayer structures.

[0136] Leno-style weaving is possible by twisting between the “warp” yams; for example warp yams can include multiple twists and can twist in either direction allowing for advance control of hole sizes and expanded leno-style weaving possibilities. See FIG.41. For example, a new type of “leno” structure can be created when leno pairs switch partners over the length of the fabric. See FIG. 42. In yet further aspects, a new class of structures can becreated where twists are included in both warp and weft directions creating bi-axial twist leno. See FIG. 53. It is also possible to combine leno techniques with woven techniques and transitions as described herein.

[0137] Weft knitting-like structures can be achieved through different methods. In one aspects, they can be created with a twisted selvage edge with the courses running in the take-up direction by using the YCMS to create an entangled wale structure. See FIG. 43. A weft knitting structure can also be made using engagement tool knitting needles that engage with the yams exiting a YCM. See FIG. 44. Knitting needles or needle beds could be dynamically mounted to an existing YCM, another floating modular planar motion stage, or other static or dynamic mounting points. This would allow the YCM to interact with the needles or the needles to interact with the YCMs. See FIG. 44.

[0138] In further aspects warp knit structures can be formed using engagement tools (e.g., needles, guides, and sinkers) to engage YCMs that provide the warp yams. See FIG. 45.

[0139] Manipulators can also help create woven, netted, or knotted structures. See FIG. 46. A pass-over method can create knotting, netting, and other complex structures. One way to manipulate yams for a pass-over would be to utilize actuated engagement tools to bring yams close to the stage so YCMs can pass over them without entanglement. See FIG. 47.

[0140] The ability of the HTSM to transition betw een classes of textiles allows developers to create entirely new classes of textile materials. For example, the HTSM allows for knitting to woven transitions (see FIG. 55), braid to coil transitions (see FIG. 52), or braid to covered transitions. In particular aspects the textile structure includes a transition from one structure type to another structure type, wherein the transition comprises a transition of braiding to weaving, knitting to braiding, weaving to knitting, twisting to braiding, or any combination thereof.

[0141] The flexibility of the HTSM allows users to control variables such as YCM speed, acceleration and position, take-up speed acceleration and position, and relative tension between the YCM and take-up system. Engagement tools add further methods for expanding textile structure designs.

[0142] In further aspects, YCMs could be manipulated to change between modular planar motion stage (200) areas (see FIGS. 56 and 57) through bridges or physical transport through a manipulator or operator.

[0143] As discussed, gaps may be included between each modular planar motion stage (200) (FIG. 6), or the modular planar motion stage (200) may include an opening thatallows longitudinal yams (FIG. 6) or core yams (FIG. 7) to pass through the stage to engage in the textile structure if required. Similarly, the gap or opening can allow for the passage of preforms or mandrels that the textile can form around or intertwine with (FIG. 8).Engagement tools may also be used to operate in these gaps / holes.

[0144] Each YCM has a unique identifier (FIG. 49) which is recognized by the HTSM and enables the identification of a Y CM or engagement tool while on the stage. In some aspects the HTSM can detect when a YCM spool is running low based on sensors in the YCM, such as by measuring the weight of a YCM magnetically (FIG. 50) or by making predictions based on yam usage through software simulations. When a YCM runs out of yam, it can be reloaded or swapped with a new YCM manually or automatically.

[0145] By modifying the shape of the modular planar motion stage (200), YCMs can enter a '‘pit-stop’’ area where yam tension can be maintained, and the swapping and splicing between the exhausted YCM and the replacement YCM can occur. See FIG. 46. Battery swapping may also occur in the pit-stop area, and can be performed manually or automatically. Battery swapping can also occur using automated engagement tools as described herein. Splicing of the yams can happen through a variety of techniques, including but not limited to knots, entanglement, ultrasonic and thermal bonding. The same approaches can be used to introduce or terminate yams at any point in the textile structure.

[0146] In some aspects the YCM can “self-load” a replacement yam spool (102) using the tensioning device (104) used for tensioning which eliminates the need for a second machine to do spool winding.

[0147] The YCM and HTSM described herein offer the following innovations and advantages over conventional systems and methods:- Flexibility in textile structure and design freedom;- Seamless transitions between different fabric types within a single textile;Automated reload and yam management systems which enhance efficiency and reduce downtime;Scalability and adaptability based on the number of YCMs and engagement tools required;Advanced take-up system for adaptable speed and orientation;- Flexible modular planar motion stage design for customized motion paths; and- Intelligent yam management systems.

[0148] Various combinations of elements of this disclosure are encompassed by this disclosure, e.g., combinations of elements from dependent claims that depend upon the same independent claim.Aspects of the Disclosure

[0149] In various aspects, the present disclosure pertains to and includes at least the following aspects.

[0150] Aspect 1. A yam carrier module (Y CM) ( 100) comprising: a motion platform (101) comprising a plurality of permanent magnets configured to generate a magnetic field in the presence of an external electromagnet; ayam spool (102) attached to the motion platform (101) onto which a yam (103) may be wound; a tensioning device (104) operatively connected to the yam spool (102); a tension sensor (105) capable of measuring tension on the yam (103); a YCM controller (106); a wireless communication module (107); and a battery (108). wherein the YCM controller (106) is configured to receive data from the tension sensor (105) and operate the tensioning device (104) to adjust the tension on the yam (103), and wherein the wireless communication module (107) is configured to receive control commands for the Y CM controller ( 106).

[0151] Aspect 2. The YCM according to Aspect 2, wherein the YCM (100) further comprises an eyelet (109) for guiding the yam (103).

[0152] Aspect 3. The YCM according to Aspect 1 or 2, wherein one or more of the yam spool (102), tensioning device (104), tension sensor (105), YCM controller (106), wireless communication module (107), and battery (108) is removable from the YCM (100).

[0153] Aspect 4. The YCM according to any one of Aspects 1 to 3, wherein the battery (108) is rechargeable without removing it from the YCM (100). or is removable from the YCM (100) so that it may be replaced with another battery.

[0154] Aspect 5. The YCM according to any one of Aspects 1 to 4, wherein the YCM controller (106) is configured to monitor yam consumption over time and estimate yam (103) remaining on the yam spool (102).

[0155] Aspect 6. The YCM according to Aspect 5. wherein the estimate is based on one or more of (1) historical feed rates, (2) a simulation of expected usage, or (3)measurement of an effective magnetic force required to levitate the YCM in response to the external electromagnet, wherein the measurement of effective magnetic force required to levitate the YCM changes in response to an amount of yam remaining on the spool.

[0156] Aspect 7. The YCM according to any one of Aspects 2 to 6, wherein theYCM further comprises an actuator to alter a position or height of the eyelet (109).

[0157] Aspect 8. A hybrid textile structure machine (HTSM) (10), comprising: a. at least one YCM (100) according to any one of Aspects 1 to 7; b. at least one modular planar motion stage (200) comprising an array of stage electromagnets configured to engage with the permanent magnets on the at least one YCM (100) and cause the at least one YCM (100) to levitate on the at least one modular planar motion stage (200); and c. a central controller (300) configured to operate the array of stage electromagnets and provide individual motion commands to the at least one YCM controller, wherein the at least one YCM (100) is movable over the at least one modular planar motion stage (200) without predefined tracks.

[0158] Aspect 9. The HTSM (10) according to Aspect 8. wherein the HTSM comprises a plurality7of YCMs (100), wherein the central controller (300) provides instructions to the stage electromagnets and YCM controller (106) on each of the plurality7of YCMs (100) to control the motion of the plurality of YCMs (100) and the yam tension on the yam (103) of each of the plurality of YCMs (100) to produce a textile structure.

[0159] Aspect 10. The HTSM (10) according to Aspect 9, wherein the textile structure comprises a woven structure, a braided structure, a knitted structure, a twisted structure, or a hybrid structure comprising a combination thereof.

[0160] Aspect 11. The HTSM (10) according to Aspect 9 or 10. wherein each of the plurality of YCMs (100) move over the at least one modular planar motion stage (200) on a programmed path, and wherein the programmed path adapts in real time based on motion or performance variations detected by the central controller (300) or plurality7of YCM controllers (106).

[0161] Aspect 12. The HTSM (10) according to any one of Aspects 8 to 11, wherein the modular planar motion stage comprises a single modular planar motion stage (200) or a plurality7of modular planar motion stages (200) connectable with or without a phy sical gap (201).

[0162] Aspect 13. The HTSM according to Aspect 12, wherein the modular planar motion stage comprises a plurality of modular planar motion stages (200) comprising at leastone gap (201) between the modular planar motion stages (200) to allow the passage of yams, mandrels, or engagement tools through the gap (201).

[0163] Aspect 14. The HTSM according to any one of Aspects 8 to 13, wherein the HTSM comprises a charging zone (202) comprising a system for recharging the battery (108) on one or more of the YCMs.

[0164] Aspect 15. The HTSM according to Aspect 14, wherein the battery (108) is recharged by inductive coupling, electrical contact, or magnetic forces provided to the modular planar motion stage (200).

[0165] Aspect 16. The HTSM according to any one of Aspects 9 to 15, wherein the textile structure includes a transition from one structure type to another structure type, wherein the transition comprises a transition of braiding to weaving, knitting to braiding, weaving to knitting, twisting to braiding, or any combination thereof.

[0166] Aspect 17. The HTSM according to any one of Aspects 8 to 16, wherein the HTSM comprises one or more engagement tools configured to perform at least one of the following activities: manipulate a position of the yam or a plurality of yams; knot the yam or a plurality of yams; cut the yam or a plurality of yams; fuse the yam or a plurality of yams; introduce a new yam or plurality of yams into the textile; remove one or more yams from the textile; or assist with convergence zone formation.

[0167] Aspect 18. The HTSM according to Aspect 17, wherein the one or more engagement tools are mounted on the at least one modular planar motion stage (200), one or more of the YCMs (100), or on a platform that is separate from the at least one modular planar motion stage (200).

[0168] Aspect 19. The HTSM according to any one of Aspects 8 to 18, further comprising a dynamic take-up system (400) configured to adjust (1) a position of a yam convergence zone relative to the modular planar motion stage (200) or (2) movement of a fabric structure formed by the HTSM.

[0169] Aspect 20. The HTSM according to Aspect 19, w herein the position of the yam convergence zone relative to the at least one modular planar motion stage (200) is adjustable in three directions including an X-direction and Y-direction corresponding to a length and width of the at least one modular planar motion stage (200) and a Z-direction corresponding to a height from the at least one modular planar motion stage (200).

[0170] Aspect 21. The HTSM according to any one of Aspects 8 to 20, wherein the controller (300) is configured to detect yam failures or entanglements and dispatch an engagement tool to perform corrective actions.

[0171] Aspect 22. A method of producing a hybrid textile structure, comprising: providing a HTSM according to any one of Aspects 8 to 21. wherein the HTSM comprises a plurality of YCMs according to any one of Aspects 1 to 7; controlling motion of each of the plurality of YCMs along unconstrained motion paths; regulating yam tension on the yam on each of the plurality of YCMs; and coordinating motion and tension across multiple YCMs to interlace yams in a structure selected from one or more of a weave, a knit, a twist, a braid, or a combination thereof.

[0172] Aspect 23. The method according to Aspect 22, further comprising transitioning between one structure to another during formation of the structure.

[0173] Aspect 24. The method according to Aspect 22 or 23, further comprising modifying a position of a yam convergence zone by motion of a take-up system or consolidation ring.

[0174] Aspect 25. The method according to any one of Aspects 22 to 24, further comprising detecting a low yam supply on one or more of the plurality of YCMs.

[0175] Aspect 26. The method according to any one of Aspects 22 to 25, further comprising using one or more engagement tools to manipulate yam paths, wherein manipulating yam paths comprises introducing new yams or terminating existing yams during production of the structure.

[0176] Aspect 27. A textile structure formed according to the method according to any one of Aspects 22 to 26.EXAMPLES

[0177] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the articles, devices and / or methods claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the disclosure. There are numerous variations and combinations of operating conditions that can be used to optimize the product obtained from the described process. Only reasonable and routine experimentation will be required to optimize such process conditions.

[0178] To demonstrate that the YCM and HTSM described herein could be suitable for forming complex textile structures such as those described herein, a prototype including early stage mechanical tensioners (analogous to the YCM described herein) was operated ona commercially available planar motor gantry (analogous to the modular planar motion stage described herein) to form textile structures. An example of the prototype is shown in FIG. 61. The prototype was used to form the textile structures, including knit (FIGS. 62A and 62B) and woven (FIGS. 62C and 62D) structures. As shown in the figures, while the prototype enabled the production of certain textile structures, they are relatively loose and not necessarily suitable for all commercial and personal applications. Improvements to the YCM and HTSM described herein allow for the formation of more improved and complex textile structures such as those described in the disclosure.

[0179] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other aspects can be used, such as by one of ordinary’ skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed aspect. Thus, the following claims are hereby incorporated into the Detailed Description as examples or aspects, with each claim standing on its own as a separate aspect, and it is contemplated that such aspects can be combined with each other in various combinations or permutations. The scope of the disclosure should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

CLAIMSWhat is claimed is:

1. A yam carrier module (YCM) (100) comprising: a motion platform (101) comprising a plurality’ of permanent magnets configured to generate a magnetic field in the presence of an external electromagnet; ayam spool (102) attached to the motion platform (101) onto which ayam (103) may be wound; a tensioning device (104) operatively connected to the yam spool (102); a tension sensor (105) capable of measuring tension on the yam (103); a YCM controller (106); a wireless communication module (107); and a battery (108), wherein the YCM controller (106) is configured to receive data from the tension sensor (105) and operate the tensioning device (104) to adjust the tension on the yam (103), and wherein the wireless communication module (107) is configured to receive control commands for the YCM controller (106).

2. The YCM according to claim 2, wherein the YCM (100) further comprises an eyelet (109) for guiding the yam (103).

3. The YCM according to claim 1 or 2, wherein one or more of the yam spool (102), tensioning device (104), tension sensor (105), YCM controller (106), wireless communication module (107), and battery (108) is removable from the YCM (100).

4. The YCM according to any one of claims 1 to 3, wherein the battery (108) is rechargeable without removing it from the YCM (100), or is removable from the YCM (100) so that it may be replaced with another batten .

5. The YCM according to any one of claims 1 to 4, wherein the YCM controller (106) is configured to monitor yam consumption over time and estimate yam (103) remaining on the yam spool (102).

6. The YCM according to claim 5, wherein the estimate is based on one or more of (1) historical feed rates, (2) a simulation of expected usage, or (3) measurement of an effective magnetic force required to levitate the YCM in response to the external electromagnet, wherein the measurement of effective magnetic force required to levitate the YCM changes in response to an amount of yam remaining on the spool.

7. The YCM according to any one of claims 2 to 6, wherein the YCM further comprises an actuator to alter a position or height of the eyelet (109).

8. A hybrid textile structure machine (HTSM) (10), comprising: a. at least one YCM (100) according to any one of claims 1 to 7; b. at least one modular planar motion stage (200) comprising an array of stage electromagnets configured to engage with the permanent magnets on the at least one YCM (100) and cause the at least one YCM (100) to levitate on the at least one modular planar motion stage (200); and c. a central controller (300) configured to operate the array of stage electromagnets and provide individual motion commands to the at least one Y CM controller, wherein the at least one YCM (100) is movable over the at least one modular planar motion stage (200) without predefined tracks.

9. The HTSM (10) according to claim 8, wherein the HTSM comprises a plurality of YCMs (100), wherein the central controller (300) provides instructions to the stage electromagnets and YCM controller (106) on each of the plurality of YCMs (100) to control the motion of the plurality of YCMs (100) and the yam tension on the yam (103) of each of the plurality of YCMs (100) to produce a textile structure.

10. The HTSM (10) according to claim 9, wherein the textile structure comprises a woven structure, a braided structure, a knitted structure, a twisted structure, or a hybnd structure comprising a combination thereof.

11. The HTSM (10) according to claim 9 or 10, wherein each of the plurality ofYCMs (100) move over the at least one modular planar motion stage (200) on a programmed path,and wherein the programmed path adapts in real time based on motion or performance variations detected by the central controller (300) or plurality of YCM controllers (106).

12. The HTSM (10) according to any one of claims 8 to 11, wherein the modular planar motion stage comprises a single modular planar motion stage (200) or a plurality of modular planar motion stages (200) connectable with or without a physical gap (201).

13. The HTSM according to claim 12, wherein the modular planar motion stage comprises a plurality of modular planar motion stages (200) comprising at least one gap (201) between the modular planar motion stages (200) to allow the passage of yams, mandrels, or engagement tools through the gap (201).

14. The HTSM according to any one of claims 8 to 13, wherein the HTSM comprises a charging zone (202) comprising a system for recharging the battery (108) on one or more of the YCMs.

15. The HTSM according to claim 14, wherein the battery (108) is recharged by inductive coupling, electrical contact, or magnetic forces provided to the modular planar motion stage (200).

16. The HTSM according to any one of claims 9 to 1 , wherein the textile structure includes a transition from one structure type to another structure type, wherein the transition comprises a transition of braiding to weaving, knitting to braiding, weaving to knitting, twisting to braiding, or any combination thereof.

17. The HTSM according to any one of claims 8 to 16, wherein the HTSM comprises one or more engagement tools configured to perform at least one of the following activities: manipulate a position of the yam or a plurality’ of yams: knot the yam or a plurality’ of yams: cut the yam or a plurality of yams; fuse the yam or a plurality of yams; introduce a new yam or plurality of yams into the textile; remove one or more yams from the textile; or assist with convergence zone formation.

18. The HTSM according to claim 17. wherein the one or more engagement tools are mounted on the at least one modular planar motion stage (200), one or more of the YCMs(100), or on a platform that is separate from the at least one modular planar motion stage (200).

19. The HTSM according to any one of claims 8 to 18, further comprising a dynamic take-up system (400) configured to adjust (1) a position of a yam convergence zone relative to the modular planar motion stage (200) or (2) movement of a fabric structure formed by the HTSM.

20. The HTSM according to claim 19, wherein the position of the yam convergence zone relative to the at least one modular planar motion stage (200) is adjustable in three directions including an X-direction and Y-direction corresponding to a length and width of the at least one modular planar motion stage (200) and a Z-direction corresponding to a height from the at least one modular planar motion stage (200).

21. The HTSM according to any one of claims 8 to 20, wherein the controller (300) is configured to detect yam failures or entanglements and dispatch an engagement tool to perform corrective actions.

22. A method of producing a hybrid textile structure, comprising: providing a HTSM according to any one of claims 8 to 21, wherein the HTSM comprises a plurality of YCMs according to any one of claims 1 to 7; controlling motion of each of the plurality of YCMs along unconstrained motion paths; regulating yam tension on the yam on each of the plurality of YCMs; and coordinating motion and tension across multiple YCMs to interlace yams in a structure selected from one or more of a weave, a knit, a twist, a braid, or a combination thereof.

23. The method according to claim 22, further comprising transitioning between one structure to another during formation of the stmcture.

24. The method according to claim 22 or 23, further comprising modifying a position of a yam convergence zone by motion of a take-up system or consolidation ring.

25. The method according to any one of claims 22 to 24, further comprising detecting a low yam supply on one or more of the plurality of YCMs.

26. The method according to any one of claims 22 to 25, further comprising using one or more engagement tools to manipulate yam paths, wherein manipulating yam paths comprises introducing new yams or terminating existing yams during production of the structure.

27. A textile structure formed according to the method according to any one of claims 22 to 26.

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