Crank apparatus and manufacturing method

Abstract

A crank comprising a coupling (1110) comprising: a first coupling fiber layer (210) and a third coupling fiber layer (230), each layer comprising one or more filaments (100) comprising fibers, the filaments arranged in a first path (210P1) forming a contour (210C1) comprising one or more splines (210S1, 210S2) matching a contour of one or more grooves (1510) of a splined coupling (1500) having a first axis of revolution (Z1), and a second path (210P2) that is concentric to the first path; and a second coupling fiber layer (220), comprised between the first coupling fiber layer and the third coupling fiber layer and comprising one or more filaments (100) comprising fibers, wherein one or more of the filaments of the second coupling fiber layer are arranged in a third path (220P1) at least a portion of which is concentric with a sector (210AS) of the first path and of the second path around the first axis (Z1).

Description

Crank Apparatus and Manufacturing MethodField

[0001] This disclosure relates to cranks comprising composite materials.Summary

[0002] For example, this disclosure presents a coupling comprising: a first coupling fiber layer and a third coupling fiber layer, each layer comprising one or more filaments comprising fibers, the filaments being arranged in a first path forming a contour comprising one or more splines matching a contour of one or more grooves of a splined coupling having a first axis of revolution, and a second path that is concentric to the first path; and a second coupling fiber layer, comprised between the first coupling fiber layer and the third coupling fiber layer and comprising one or more filaments comprising fibers, wherein one or more of the filaments of the second coupling fiber layer are arranged in a third path at least a portion of which is concentric with a sector of the first path and of the second path around the first axis.

[0003] For example, the disclosure presents a crank comprising one or more splined couplings, wherein the crank comprises one or more webs extending from one or more of the couplings in a web plane set at an orientation comprised in a range from -30° to +30° with respect to a plane orthogonal to the first axis of the coupling.

[0004] For example, the disclosure presents a method for manufacturing the crank comprises: forming one or more of the splined couplings, forming one or more of the webs; and forming one or more of the beams bonded to one or more of the webs, wherein the forming one or more of the splined couplings comprises: forming a first coupling fiber layer by depositing one or more filaments comprising fibers in a first path forming a contour comprising one or more splines matching a contour of one or more grooves of a splined coupling having a first axis of revolution, and depositing one or more filaments comprising fibers in a second path that is concentric to the first path; and forming a second coupling fiber layer by bonding one or more filaments comprising fibers to the first coupling fiber layer; and forming a third coupling fiber layer by bonding one or more filaments comprising fibers to the second coupling fiber layer, wherein the forming the second coupling fiber layer comprises depositing one or more filaments in a third path at least a portion of which is concentric with a sector of the first path and of the second path around the first axis.Brief description of drawings

[0005] Fig. 1 is an isometric view of a crank presented with respect to a spindle comprising a splined end.

[0006] Fig. 2 is an isometric exploded view of 3 layers of a splined coupling, for example comprised within the crank, each layer comprising filaments comprising fiber.

[0007] Fig. 3A is a close-up of Fig. 2, showing bondings from a first layer to a third layer.

[0008] Fig. 3B is a top view of the first layer shown in Fig. 3A.

[0009] Fig. 3C is a further expanded view of Fig. 3A showing filaments continuous layer-to-layer filament path.

[0010] Fig. 4A is a side view of a stack comprising 3 layers comprising filaments and 2 layers bonding pairs of layers comprising filaments.

[0011] Fig. 4B is a side view of a stack of layer comprising filaments wherein each of the first layer and the last layer of the stack are arranged as an O-loop-comprising layer.

[0012] Fig. 5A is a top view of a layer within a stack, the layer comprising filaments arranged in one or more of an S-loop, a circular arc, and an X-junction.

[0013] Fig. 5B is a top view of a layer, for example stacked against the layer of Fig. 5A, comprising filaments arranged in one or more of an O-loop, a circular arc, and an X-junction.

[0014] Fig. 5C is a top view of a layer within the stack, comprising filaments arranged in one or more of contour comprising splines, an O-loop, an S-loop, an arc path tracing a plurality of spline contours, and an X-junction.

[0015] Fig. 5D is a top view of another layer within the stack, comprising filaments arranged in one or more of a contour comprising splines, an O-loop, and an X-junction.

[0016] Fig. 5E is a top view of a further layer within the stack, comprising filaments arranged in one or more of a contour comprising splines, an O-loop, an S-loop, a circular arc, and an X- junction comprising one or more filaments arranged to overpass filament segments shown in the X-junction of Fig. 5D.

[0017] Fig. 6 is a side view of a longitudinal cross-section along the crank’s mid-line showing a cross-section of a web.

[0018] Fig. 7A is a symbolic representation for a first layout of beams connecting a first coupling to a second coupling and arranged against a first face of the web.

[0019] Fig. 7B is a symbolic representation for a second layout of beams, arranged as a mirror of the first layout, connecting the first coupling to the second coupling and arranged against a second face of the web.

[0020] Fig. 8 is an expanded view of the side of Fig. 6 showing a mirror arrangement of filament layers in each of the mirror web and beam structures shown in Figs. 7, 7A, and 7B.

[0021] Fig. 9A is a side, mid-line cross section of a first crank preform and its layers used for manufacturing a crank comprising an inclined web.

[0022] Fig. 9B is a side view of the first crank preform and its layers.

[0023] Fig. 9C is a side, mid-line cross section of a second crank preform and its layers used for manufacturing the crank comprising an inclined web.

[0024] Fig. 9D is a side view of the second crank preform and its layers.

[0025] Fig. 9E is a side, mid-line cross section of the crank, showing the first crank preform and the second crank preform arranged in a web-to-web mirror configuration after a step of deforming, for example inside a mold.

[0026] Fig. 9F is a side view of the crank of Fig. 9E.

[0027] Fig. 9G is a side, mid-line cross section, of one or more of a deformed version of the crank of Fig. 9E and an assembly of the crank preforms of Figs. 9A and 90.

[0028] Fig. 9H presents a variation of the crank of Fig. 9G wherein the web comprises one or more curves.

[0029] Fig. 10A is an isometric view of a hollow crank assembly comprising 2 bonded crank shells reinforced by 2 U-shaped profiles.

[0030] Fig. 10B is a partial exploded view of the hollow crank of Fig. 10A showing the 2 bonded crank shells and the 2 U-shaped profiles.

[0031] Fig. 10C is an exploded view of the hollow crank of Figs 10A and 10B showing the beams and a plurality of webs used for forming each crank shell.

[0032] Fig. 11 is a block diagram for a method for manufacturing a crank.

[0033] Fig. 12 is a side view of a system for manufacturing preforms.

[0034] Fig. 13 is cross-section side view of a mold comprising the crank.

[0035] Fig. 14 is a perspective view of a bicycle crank comprising components assembled using electrically-conductive tows.

[0036] Fig. 15A is a top view of a bicycle crank onto which a foldable reinforcement plate is about to be folded.

[0037] Fig. 15B is a cross-section of the bicycle crank and of the foldable reinforcement plate.Detailed description

[0038] This disclosure relates to cranks 1000, 1001, 1002, 1005, 1006, 1007 or crank arms comprising composite materials, for example comprising fibers. For example, a bicycle comprises one or more cranks to transfer a motion of one or more of a leg and an arm of a cyclist to rotate a crankset of a drivetrain. Crank arms have commonly been made of metal and added substantial weight to a bicycle. An effort to reduce the weight of crank arms has led to the development of shell-based designs, for example using metals, some of which tend to fail due to high loads on the shell-based torsion box design on which the crank arms are based. A further effort has led to the development of crank arms using fiber-reinforced materials.

[0039] The development of automated additive manufacturing systems 2000, for example for depositing fiber-comprising filaments 100 along paths that take into account force transmission and time-constrained manufacturing, enables the development of crank examples and methods presented in this disclosure. For example, the filament 100 comprises continuous fibers. For example, this disclosure presents so-called monolithic crank examples 1000M and hollow crank examples 1000H. For example, manufacturing of the crank examples comprised one or more steps of material deposition, for example comprising one or more of fibers and polymers, and molding, for example comprising one or more of preform deforming, stamping, compression molding, and overmolding.

[0040] Fig. 1 is an isometric view of a crank 1000 presented with respect to a spindle 1500 comprising a splined end 1510. For example, the crank comprises one or more couplings 1110, 1120. For example, the crank 1000, for example configured as a so-called monolithic crank 1000M, is formed from one or more crank preforms, for example a first crank preform 1001 and a second crank preform 1002. For example, a crank preform 1001, 1002 is usable as a crank 1000, albeit with a mechanical strength that is inferior to that of a crank manufactured from one or more preforms having undergone one or more of pressing, stamping, molding, and compression molding.

[0041] For example, each of the couplings have an axis, for example an axis of revolution Z1, Z2. For example, one or more of the couplings comprises a splined coupling 1110. For example, the crank comprises one or more webs 1050, 1051, 1052. For example, one or more of the webs extend from one or more of the couplings in one or more web planes. For example, the web plane set at an orientation comprised in a range from -30° to +30°, for example from -20° to +20°, for example from -10° to +10°, for example from 0° to +12°, for example from +4° to +10°, with respect to a plane orthogonal to the axis Z1 , Z2 of the coupling. For example, the web orientation is in one or more of pitch and roll assuming the Z1 axis is a yaw axis. For another example, once the crank is mounted on a bicycle and the pedal cranks rotate around a pitch axis, the web orientation is on one or more of yaw and roll with respect to a frame of the bicycle.

[0042] For example, a first face 1051 F1 of the web 1050 and an opposite second face 1050F2 of the web each comprise one or more beams 1010, 1020, 101 OX, 1020X. For example, the web comprises one or more of one or more side beams 1010, 1020 and one or more joining beams 101 OX, 1020X. For example, one or more of the beams are bonded to the web. For example, the beams comprise one or more filaments 100 comprising fibers. For example, a longitudinal direction 1010D, 1020D, 1010XD, 1020XD of the filaments are extending from one or more first couplings 1110, having a first axis of revolution Z1 , towards one or more second couplings 1120, having a second axis of revolution Z2 that is offset from the first axis Z1.

[0043] Fig. 6 is a side view of a longitudinal cross-section along the crank’s mid-line showing a cross-section of a web. Fig. 7A is a symbolic representation for a first layout 1010LO1 of beams connecting a first coupling to a second coupling and arranged against the first face 1050F1 of the web. Fig. 7B is a symbolic representation for a second layout 1010LO2 of beams, for example arranged as a mirror of the first layout, for example connecting the first coupling to the second coupling and arranged, for example against a second face of the web.

[0044] For example, one or more of the beams are arranged in a first layout 1010LO1 against the first face 1050F1 of the web. For example, one or more of the beams are arranged in a second layout 1010LO2 against the second face 1050F2 of the web. For example the second layout is a mirror arrangement of the first layout.

[0045] To summarize, this disclosure presents, for example, a crank 1000, 1001 , 1002comprising one or more splined couplings 1110 according to any one of claims 1 to 19, wherein the crank comprises one or more webs 1050, 1051 , 1052 extending from one or more of the couplings in a web plane set at an orientation comprised in a range from -30° to +30° with respect to a plane orthogonal to the first axis Z1 of the coupling. For example, a first face 1051 F1 of the web 1050 and an opposite second face 1050F2 of the web each comprise one or more beams 1010, 1020, 101 OX, 1020X bonded to the web and comprising one or more filaments 100 comprising fibers, a longitudinal direction 1010D, 1020D, 1010XD, 1020XD of the filaments extending towards one or more second couplings 1120 having a second axis of revolution Z2 that is offset from the first axis Z1 . For example, a second layout 1010LO2 of the one or more beams 1010, 1020, 101 OX, 1020X arranged against the second face 1050F2 of the web 1050 is a web-surface-based mirror of a first layout 1010LO1 of the one or more beams arranged against the first face 1050F1 of the web. For example, the crank 1000 comprises one or more lids 1080, for example extending longitudinally from the first coupling to the second coupling, for example masking one or more of the beams. For example, the lids 1080 are fastened to the crank by one or more of an adhesive, a welding, a screw, a rivet, and a snapfitting, for example against one or more of the couplings, the beams, the webs, and an opposite lid.

[0046] Fig. 8 is an expanded view of the side of Fig. 6 showing a mirror arrangement of filament layers in each of the mirror web and beam structures shown in Figs. 7, 7A, 7B. For example, the crank comprises a first layup 200111 comprising one or more layers 1010L1 , 1010L2, 1010L3 comprising one or more of the filaments 100 comprising fibers. For example, the layers are stacked in a first direction Z extending away from the first face 1050F1 of the web 1050. For example, the crank comprises a second layup 200LI2 comprising one or more layers 1010L1 , 1010L2, 1010L3 comprising one or more of the filaments 100 comprising fibers. For example, the layers are stacked in a second direction -Z extending away from the second face 1050F2 of the web 1050. For example, the second layup is a web-surface-based mirror of the first layup. For example, the number of layers comprised in a crank is a function of the thickness in the Z- direction of filaments and the thickness of the crank. For a bicycle crank, the number of layers using fiber-comprising tapes as filaments having a thickness comprised in a range from 0.1 mm to 0.2 mm is in a range from 50 to 200 layers, for example from 60 to 100 layers.

[0047] For example, the web 1050 comprises one or more layers comprising one or more filaments 100 comprising fibers. For example, one or more of the layers at one or more of the faces 1050F1 , 1050F2 of the web comprise one or more filaments 100 having an orientation that is parallel to one or more of the fibers at a surface of one or more of the beams 1010, 1020, 101 OX, 1020X bonded to the web.

[0048] For example, the crank comprises a first layer 1050L1 at a face 1050F1 of the web 1050, comprising a first plurality of parallel filaments 100 oriented at a first orientation 1050A1comprised in a range from 1° to 60° with respect to a longitudinal direction X1 from a first coupling, for example from a center of the first coupling, to a second coupling, for example to a center of the second coupling. For example, the crank comprises a second layer 1050L2, bonded to the first layer, comprising a second plurality of parallel filaments oriented at a second orientation 1050A2 comprised in a range from -5° to +5° with respect to the longitudinal direction. For example, the crank comprises a third layer 1050L3, bonded to the second layer, comprising a plurality of parallel filaments oriented at a third orientation 1050A3 that is within a range from -5° to +5° from a mirror orientation of the first orientation with respect to the longitudinal direction.

[0049] For example, one or more webs 1050 comprise the one or more beams 1010, 1020, 101 OX, 1020X on a first face 1050F1 of the web and on a second face 1050F2 of the web.

[0050] Fig. 9A is a side, mid-line cross section of a first crank preform 1001 comprising layers used for manufacturing a crank 1000, 1000Z comprising an inclined web 1050Z. Fig. 9C is a side, mid-line cross section of a second crank preform 1002 comprising layers used for manufacturing the crank. For example, the first crank preform 1001 comprises a first web 1051. For example, the second crank preform 1002 comprises a second web 1052. For example, one or more of the crank preforms 1001, 1002 comprise one or more coupling portions 1110P1 , 1110P2, 1120P1 , 1120P2. For example, one or more of a first coupling portion 1110P1 and a second coupling portion 1120P1 of the first crank preform 1110 have geometric characteristics, for example in one or more of dimensions and contour, matching geometric characteristics of one or more of a first coupling portion 1210P2 and a second coupling portion 1220P2 of the second crank preform 1120. For example, the matching geometric characteristics include one or more of: a concentric geometry between a coupling portion 1110P1 , 1120P1 of a first crank preform and a coupling portion 1110P2, 1120P2 of a second crank preform; and a mechanical fitting arrangement wherein a coupling portion of the first crank preform mechanically matches with a corresponding coupling portion of the second crank preform to form an integrated coupling 1110, 1120. For example, the matching is one or more of formed and completed in a manufacturing step comprising one or more of pressing, stamping, molding, compression molding, and overmolding.

[0051] For example, a method 5000 for manufacturing the crank 1000Z comprising an inclined web 1050Z comprise one or more of: i) forming a first crank preform 1001; ii) forming a second crank preform 1002; and iii) bonding the first crank preform to the second crank preform in one or more steps comprising one or more of pressing, stamping, molding, compression molding, and overmolding.

[0052] Fig. 9B is a side view of the first crank preform 1001. For example, the first crank preform comprises one or more layers of material, for example layers comprising filaments 100. For example, as mentioned with respect to Fig. 2, a polymer layer, for example one or morelayers (not shown) comprising a thermoplastic adhesive, for example comprising a lower fiber volume ratio of fibers than the layers comprising filaments 100, are comprised between a first layer and a second layer comprising filaments 100. For example, the polymer layers are deposited by a fused deposition modeling nozzle. Other polymer layer examples include powders, nets, sheets, tapes, and coatings.

[0053] Fig. 9A presents a first web 1051 comprising a plurality of layers, for example in a range from 2 to 300 layers, for example from 2 to 50 layers, for example from 2 to 10 layers, for example, as illustrated, 3 layers. For example, the number of layers comprised in the web is constant across one or more of the width (for example in the Y-direction) and span (for example in the X-direction) of the web. For another example, the number of layers comprised in the web varies across one or more of the width and span of the web. For example, Fig. 9B shows that the side view comprises fewer layers than the cross-section of Fig. 9A, for example only 2 layers, extending across the span, for example in the X-direction, along the side of the crank.

[0054] Fig. 9B illustrates that the web comprises one or more beams 1010, 1020, 101 OX, 1020X comprising filaments, for example arranged in layers, having a different extent, for example in one or more of width and span. For example, Fig. 9B illustrates a beam 1020 having a staircase arrangement 1020S of layers. For example, the beam comprises one or more capping layers 1020CL, for example comprising one or more filaments 100, extending in one or more of width and span over 2 or more steps of the staircase arrangement. For example, one or more of the capping layers 1020CL join with, for example are bonded to, one or more of the layers comprised in the web 1050.

[0055] Fig. 9A further presents a cross-section of a junction of beams 1010J wherein a first joining beam 101 OX one or more of joins and intersects a second joining beam 1020X. For example, one or more of the joining beams 101 OX, 1020X comprise a plurality of layers comprising fibers, for example forming a staircase arrangement, for example in a longitudinal direction of the beam. Fig. 1 presents a crank 1000 having a beam arrangement comprising a single X-shaped junction of beams 1010J. Other examples of cranks (not shown) comprise a plurality of X-shaped junctions, for example arranged in one or more of the X and Y directions, for example as in a truss structure. For example, a crank comprises one or more X-shaped junctions wherein the beams are oriented at an angle of about 45°, within a tolerance of 5°, with respect to a longitudinal axis of the crank. The longitudinal axis passes, for example, from a center of a first coupling to a center of a second coupling.

[0056] Figs. 9A, 9B present, for example, a crank preform wherein an exposed surface of a first beam 1020X, for example a surface exposed towards the Z-direction, presents a staircase surface, and an exposed surface of a second beam 1020 presents a smooth surface, for example a staircase surface covered by one or more capping layers 1020CL.

[0057] Fig. 9C is a side, mid-line cross section of a second crank preform 1002. For example,the crank preform, for example the arrangement of layers comprising filaments 100 that it comprises, is used for manufacturing the crank 1000, for example a crank 1000Z comprising an inclined web. For example, the second crank preform 1002 is configured as a mirror arrangement of the first crank preform 1001, for example with respect to a base plane X-Y, for example corresponding to a substrate 200, for example a build plate, onto which one or more of the crank preforms are manufactured. For example, one or more of the cranks, for example one or more of the crank preforms, are manufactured by an additive manufacturing system 2000, for example configured for depositing one or more materials, for example comprising one or more of filaments 100 and polymer materials.

[0058] Fig. 9D is a side view of the second crank preform 1002. As in Fig. 9B, the side view presents a plurality of layers, for example arranged in a mirror configuration with respect to the substrate 200 of the first crank preform 1001.

[0059] Fig. 9E is a side, mid-line cross section of the crank 1000. For example, Fig. 9E presents the first crank preform 1001 and the second crank preform 1002 arranged in a web-to-web mirror configuration after a step of deforming. For example, the step of deforming comprises one or more of pressing, stamping, molding 5700, compression molding, and overmolding one or more of the crank preforms, for example inside a mold 8000. For example, one or more surfaces inside the mold have a surface finish having one or more of: a surface roughness, for example having an ISO roughness grade from N3 to N12; a textured surface; and a coated surface, for example comprising a coating applied within at least a portion of the mold using a vapor deposition process, for example a plasma-enhanced chemical vapor deposition process. For example, at least surface portions inside the mold that contact one or more surfaces oriented at an angle in a range from 60° to 70° with respect to the Z-direction, for example a dominant pressing direction in one or more molding processes, comprise the surface finish.

[0060] Fig. 13 is cross-section side view of a mold 8000 comprising the crank 1000. For example, the mold comprises a lid or piston 8010, for example connected to one or more motion actuators 8040, for example imparting motion in one or more directions, for example along the Z-axis. For example, the mold comprises a first cavity component 8020, for example comprising one or more ejector pins 8050, for example onto which one or more preforms are placed for molding 5700, for example along with one or more inserts 1210. For example, the mold further comprises a second cavity component 8030, for example comprising one or more motion actuators 8040. For example, a method of molding 5700 comprises one or more of: i) placing the preforms against one or more of the first cavity component and the second cavity component; ii) heating the mold to a temperature equal to or greater than a glass transition temperature of one or more polymers comprised in the preforms; iii) one or more of closing the mold and pressing the preforms; iv) retracting the second cavity component from the mold; v) opening the mold; and vi) actuating the ejector pins and ejecting the crank from the mold.

[0061] For example, the first crank preform 1001 and the second crank preform 1002 are placed in a mirror arrangement inside the mold 8000. Figs. 9E, 9F, 9G, 9H illustrate the bonding surface between the first crank preform and the second crank preform as a bonding line 300. For example, one or more of a hollow screw and a hollow nut 1220 are placed one or more of against and within the crank preforms, for example one or more of against and within the couplings 1110, 1120.

[0062] For example, as shown in Fig. 8, one or more of the hollow screw and the hollow nut comprise a chamfered or rounded transition from a tubular portion of the screw or nut, to a flange portion. For example, one or more layers comprised close to a surface of a coupling, for example within 1 to 10 layers, for example within 5 layers, comprise fewer filaments tracking an inner circumference of the coupling. For example, one or more of the couplings comprise from 1 to 5 fewer filaments lining the inner circumference of the coupling for a given layer close to the surface of the coupling, for example forming a chamfered or rounded recess 1120R comprised in the stack of layers 500S close to the surface of the coupling.

[0063] For example, one or more of the mold and crank preforms are heated, for example to a temperature greater than a glass transition temperature of a polymer comprised in the filaments comprised in the crank preforms. For example, the step of deforming comprises pressing the crank preforms against each other and, for example, bonding the substrate-side surface of the web of the first crank preform against the substrate-side surface of the web of the second crank preform.

[0064] For example, the pressing introduces tensile forces within the filaments comprised in the beams. For example, the tensile forces are alleviated in some layers as shown in Figs. 5C, 5D, and 5E by continuity of the filament within the spline patterns which, for example, provide through their wavy pattern a margin to extend the length of the beams by reduction of the peak- to-peak amplitude of the waves by tension of filaments within the beams. For example, further alleviation is provided by cuts in the filaments within the beams. For example, in a method for deforming the crank preforms, for example the preforms heated to a temperature greater than the polymer glass transition temperature, the cuts let the ends fo filaments part from each other and filaments to slide against each other as the beam extend under tension.

[0065] Fig. 9F is, for example, a side view of the crank of Fig. 9E. As Fig. 9F reveals the layout and orientation of filament layers within a side beam 1010, 1020, namely a second side beam 1020 shown in Fig. 1 , Fig. 9F is, for example, a longitudinal cross-section of the side beam. Figs. 9E and 9F each show an oblique bonding line 300 extending from the first coupling to the second coupling. Although the bonding lines 300 in the examples of Fig. 9E and Fig. 9F are not illustrated parallel in the oblique portions, a designer, human or automated layer design software, forms, for example, a different design wherein the bonding lines 300 in the mid-cross section and the side beam cross section are parallel. Note that, for example, the longitudinalextent of the one or more capping layers 1020CL is shorter, for example in the X-direction, in Fig. 9F than it is in Figs. 9B and 9D. For example, the shortening of the capping layers is transferred longitudinally along one or more of the filaments towards the wavy filament patterns of the filament portion comprised in the splined couplings. Hence, the wavy filament patterns comprised in the splined coupling have a multiple role of transferring forces from the crank to the splined coupling and alleviating tension or absorbing slack during the manufacturing steps, for example executed at one or more temperatures above glass temperature of the polymer impregnating the filaments, for example within one or more steps of pressing, stamping, bending, molding, compression molding, and overmolding.

[0066] Fig. 9G is, for example, a side, mid-line cross section, of a deformed version of the crank of Fig. 9E. For a further example, Fig. 9G, is a side mid-line cross section, of an assembly of the crank preforms of Figs. 9A and 90. For example, the crank presented in Fig. 9G is an assembly of crank preforms having undergone less deformation than the assembly presented in Fig. 9E. For yet a further example, the crank presented in Fig. 9G is the crank presented in Fig. 9E having undergone a further deforming step under heat at a temperature greater than a glass transition temperature of the polymer impregnating the filaments, for example inside a mold. For example, an angle 1010AY between a cross-sectional plane of a coupling and a line joining the first coupling to the second coupling is comprised in a range from 0° to 30°, for example from 0° to 15°, for example from 10° to 15°, for example for use as a bicycle pedal crank. For another example, the first crank preform is bonded to the second crank preform wherein the one or more webs are parallel to the cross-sectional planes of one or more of the couplings. For example, the bonding is formed using one or more of: an adhesive bonding at least the webs of the first crank preform to the second crank preform; heating of the bonding surfaces of the webs, for example using one or more of a source of infrared radiation; ultrasonic welding; stamping; molding; compression molding; and overmolding.

[0067] Fig. 9H presents, for example, a curved crank 1000S that is a variation of the crank of Fig. 9G wherein one or more of the web and the beams comprise one or more curves, for example along the longitudinal direction of the crank. For example, one or more of the webs and the beams have an S-shape, for example from a first coupling to a second coupling. For example, the surface of the web meets one or more of the couplings tangentially to a crosssection of the coupling, for example a cross-section at a surface of the coupling. For example, the curves are formed in a step of one or more of stamping, molding, and compression molding of one or more of the webs, the beams, and the crank. For a further example, the curves are formed using a curved substrate, for example using a build plate comprising a support, upon depositing the filaments 100 using the additive manufacturing system 2000.

[0068] Fig. 10A is an isometric view of a hollow crank assembly 1000H comprising crank shells, for example 2 crank shells, for example 2 bonded crank shells. For example, the hollow crankassembly is reinforced by U-shaped profiles, for example 2 U-shaped profiles. Fig. 10B is a partial exploded view of the hollow crank of Fig. 10A showing the 2 crank shells and the 2 U- shaped profiles. Fig. 10C is an exploded view of the hollow crank of Figs 10A and 10B showing the beams and a plurality of webs used for forming each crank shell.

[0069] For example, as shown in the hollow crank example, the one or more beams 1010, 1020, 101 OX, 1020X are comprised between a first of the webs 1051 and a second of the webs 1052. For example, the crank further comprises one or more hollow inserts 1210 within one or more of the couplings. For example, the inserts are axially aligned with the axis Z1 , Z2 of the coupling 1110, 1120. For example, the inserts comprise metal.

[0070] For example, the crank further comprises one or more of a hollow screw and a hollow nut 1220. For example, one or more of the screw and the nut are inserted through one or more of the couplings. For example, one or more of the screw and the nut are axially aligned with the axis Z1, Z2 of the coupling 1110, 1120. For example, for a bicycle crank application, a hollow screw has an inner diameter ranging from 10 mm to 30 mm, for example from 15 mm to 20 mm, and a flange having a diameter ranging from 12 mm to 50 mm, for example from 25 mm to 40 mm.

[0071] In greater detail, Fig. 2 is an isometric exploded view showing 3 layers, among a plurality of layers, comprised in a coupling, for example a splined coupling 1110. For example, the coupling is comprised within the crank. Fig. 2 shows, for example the layers comprising filaments comprising fibers 100. For example, other layers that are not shown, for example comprising an adhesive, for example a thermoplastic adhesive, for example comprising a lower fiber volume ratio of fibers than the layers comprising filaments comprising fibers, are comprised between the layers comprising filaments comprising fibers 100.

[0072] For example, the coupling 1110 comprises one or more of a first coupling fiber layer 210 and a third coupling fiber layer 230. For example, each layer comprises one or more filaments 100 comprising fibers. For example, the filaments are arranged in a first path 210P1 forming a contour 210C1 comprising one or more splines 210S1 , 210S2 matching a contour of one or more grooves 1510 of a splined coupling 1500 having a first axis of revolution Z1. For example, a radius of curvature of curves in the path matching a contour of one or more of the grooves and the splines is comprised in a range from 0.3 mm to 80 mm, for example from 0.5 mm to 50 mm, for example from 1 mm to 10 mm, for example from 1 mm to 5 mm, for example from 1 mm to 3 mm. For example, the filaments are arranged in a second path 210P2 that is concentric to the first path. For example, the coupling 1110 comprises one or more second coupling fiber layers 220, comprised, for example sandwiched, between the first coupling fiber layer and the third coupling fiber layer and comprising one or more filaments 100 comprising fibers. For example, one or more of the filaments of the second coupling fiber layer are arranged in a third path 220P1 at least a portion of which is concentric with a sector 210AS of the firstpath and of the second path around the first axis Z1. For example, the sector extends in a range from 20° to 360°, for example from 60° to 270°, for example from 90° to 200°, for example from 120° to 190°.

[0073] For example, the one or more filaments 100 of the second path 210P2 are comprised in the same layer 210, 230 as the one or more filaments of the first path 210P1. For example, the one or more filaments 100 of the second path 210P2 are one or more of matching with and bonded to a contour, for example an external contour, of the one or more filaments of the first path.

[0074] Fig. 3A is a close-up of Fig. 2, showing bondings 210J from the first layer to the third layer. Fig. 3B is a top view of the first layer shown in Fig. 3A. For example, one or more of the filaments of the second coupling fiber layer 220 are forming an overpass 222, for example a bonded overpass, to the one or more filaments of the first path 210P1 and of the second path 210P2. For example, one or more of the splines 210S1, 210S2 of the first coupling fiber layer 210 and one or more of the splines 230S1, 230S2 of the third coupling fiber layer 230 are stacked in a direction parallel to the first axis Z1. For example, one or more of the couplings further comprise one or more bonding joints 210J from one or more of the splines 210S1, 210S2 of the first coupling fiber layer 210 to one or more of the splines 230S1 , 230S2 of the third coupling fiber layer 230. For example, a material comprised in the bonding joint has a fiber volume ratio that is lower than a fiber volume ratio of one or more of the filaments 100 comprised in one or more of the first coupling fiber layers and the third coupling fiber layers. For example, the one or more of the bonding joints 210J extend from a sector portion of the one or more splines. For example, the one or more of the bonding joints 210J extend over a radial distance extending in range from more that one filament to, for example, up to 20 filaments, for example up to 10 filaments, for example up to 5 filaments, for example up to 2 filaments.

[0075] For example, the third path 220P1 is arranged as a circular arc over the sector 210AS. For example, a filament 100 comprised in the first path 210P1 continues as a spiral arrangement into the second path 210P2. For example, one or more filaments 100 comprised in one or more of the paths 210P1, 210P2, 230P1 , 230P2 comprised in one or more of the first layer 210 and the third layer 230 comprise a continuous layer-to-layer path 100LL one or more of into and out of one or more paths 220P1 of the second layer 220. For example, a method for forming one or more of the paths comprised in one or more of the preforms comprises one or more of translating a filament deposition system 2100 (see Fig. 12) and rotating a shoe 2101 through which a filament is deposited onto one or more of a substrate and layers comprising one or more materials, for example one or more of filaments and polymer.

[0076] For example, the coupling comprises one or more polymer layers 215, 225 comprised between two or more coupling fiber layers 210, 220, 230. For example, the polymer material comprised in the polymer layer has a fiber volume ratio that is lower than a fiber volume ratio ofone or more of the filaments 100 comprised in one or more of the coupling fiber layers.

[0077] For example, the coupling 1110 further comprises one or more beams 1010, 1020, 101 OX, 1020X comprising one or more filaments 100 comprising fibers, a longitudinal direction 1010D, 1020D, 1010XD, 1020XD of the filaments extending towards one or more second couplings 1120 having a second axis of revolution Z2 that is offset from the first axis Z1. For example, one or more of the filaments 100 extend, for example along the one or more beams, from from a first path spanning a first sector 210AS around the first axis Z1 to a second path spanning a second sector 410AS around the second axis Z2. For example, one or more of the beams 1010, 1020, 101 OX, 1020X comprise one or more filaments 100L arranged in a looping path. For example, the looping path spans one or more first sectors 210AS around the first axis Z1. For example, the looping path spans one or more second sectors 410AS around the second axis Z2. For example, the looping path comprises one or more segments 100S joining the first sector to the second sector.

[0078] For example, the coupling 1110 further comprises a web 1050, 1051 , 1052 bonded to one or more of the beams 1010, 1020, 101 OX, 1020X. For example, one or more of the faces 1050F1 , 1050F2 of the web 1050 comprises filaments 100 that are bonded to one or more of the beams. For example, the filaments having an orientation that is parallel to fibers comprised at the bonding surface of one or more of the beams 1010, 1020, 101 OX, 1020X.

[0079] For example, the coupling 1110 further comprises an O-loop-comprising layer 210-L2, 220-L2, wherein a majority of the looping paths are spanning the first sector in a first rotating direction around the first axis Z1 and the second sector in the first rotating direction around the second axis Z2. For example, the coupling 1110 further comprises an S-loop-comprising layer 210-L1, 220-L1, wherein a majority of the looping paths span the first sector in a first rotating direction around the first axis Z1 and spans the second sector in a second opposite rotating direction around the second axis Z2. For example, the coupling 1110 comprises one or more of the O-loop-comprising layer and the S-loop-comprising layer.

[0080] For example, the coupling 1110 comprises a stack 500S of layers. For example, a first end 501 of the stack of layers and a second end 502 of the stack of layers each comprise one or more of the O-loop-comprising layers 220-L2. For example, each of the O-loop-comprising layers are joining a second coupling fiber layer 220. For example, a first layer 210-L1 and a second layer 210-L2, 220-L2 comprised between the first end of the stack of layers and the second end of the stack of layers comprise an interleave layout. For example, in the interleave layout: at a junction 100J1, 100J2 of filaments comprised in the first layer, one or more filament end portions 100E1 , 100E2, 100E3 meet one or more filaments 100C1 , 100C2, 100C3 extending continuously through the junction. For example, in the interleave layout: in the second layer, one or more filaments 100C4, 100C5 are arranged parallel to the one or more filament end portions of the first layer. For example, the filaments extend continuously over the endportions through the junction.

[0081] In one sentence: the coupling 1110 comprises a stack 500S of layers, wherein a first end 501 of the stack of layers and a second end 502 of the stack of layers each comprise one or more of the O-loop-comprising layers 220-L2, each joining a second coupling fiber layer 220; and a first layer 210-L1 and a second layer 210-L2, 220-L2 comprised between the first end of the stack of layers and the second end of the stack of layers comprising an interleave layout, wherein in the interleave layout: at a junction 100J1 , 100J2 of filaments comprised in the first layer, one or more filament end portions 100E1, 100E2, 100E3 meet one or more filaments 100C1, 100C2, 100C3 extending continuously through the junction, and in the second layer, one or more filaments 100C4, 100C5 are arranged parallel to the one or more filament end portions of the first layer and extend continuously over the end portions through the junction.

[0082] Fig. 5A is a top view of a first layer 220-L1 within a stack of layers 500S. For example, the layer comprises filaments arranged in one or more of an S-loop 100S, a circular arc 210AS, 410AS, and a first X-junction 100X1. Fig. 5B is a top view of a second layer 220-L2, for example stacked against the first layer 220-L1 of Fig. 5A. For example, the second layer comprises filaments arranged in one or more of an O-loop 100L, a circular arc, and a second X-junction 100X2. For example, filaments extending continuously across the second X-junction 100X2 pass over or under, namely are intersecting in a different plane, filaments extending continuously across the first X-junction 100X1. For example, the looping filaments 100L of the second layer 220-L2 extend over or under one or more beam junctions 100J2 of the first layer 220-L1, for example wherein one or more filaments comprised in side beams 1010 are interrupted by one or more S-shaped filaments 100S looping around one or more of the couplings.

[0083] Fig. 5C is a top view of a third layer 210-L1 within the stack. For example, the third layer comprises one or more filaments arranged in one or more contours comprising splines. For example, the third layer comprises one or more of: an O-loop 100LX, for example configured in an X pattern, an S-loop 100S, for example circling around the first coupling, for example in a spline pattern, an arc path tracing a plurality of spline contours, and a third X-junction 100X3.

[0084] Fig. 5D is a top view of a fourth layer 210-L2 within the stack. For example, the fourth layer comprises filaments arranged in one or more of: a contour comprising splines; an O-loop 100L, for example comprising filaments tangentially joining the contours of a first spline coupling to a second spline coupling; and a second X-junction 100X2. For example, a layer comprises a plurality of filaments 100C6 arranged within an area enclosed by one or more of the filaments forming the X-junction and one or more of O-loop filaments tangentially joining a first coupling to a second coupling, for example against the O-loop filaments. Fig. 5D presents a third junction 100J3 wherein the endings of one or more filaments emanating from the X-junction, for example the second X-junction 100X2 are lodged or arranged in a buttress configuration within a cornerwherein filaments of a side beam 1010 join filaments surrounding the coupling. The third junction 100J3 arrangement differs from a fifth junction 100J5 presented in Fig. 5B wherein filaments have one or more of: a space to slide longitudinally against side beam filaments, for example during a step of compression molding, for example in a step wherein a geometry of the external contour of the crank is adjusted; and a further point along a length of the side beam wherein forces are redistributed between a side beam 1010, 1020 and a joining beam 101 OX, 1020X.

[0085] For example, Fig. 5E presents a filament layup or fifth layer 210-L3 combining features found in the third layer 210-L3 of Fig. 5C and fourth layer 210-L2 of Fig. 5D. For example, the fifth layer comprises one or more filaments arranged in an O-loop 100L and one or more filaments arranged in an S-loop 100S circling around the first coupling, for example in a spline pattern, in a first circular direction and circling around the second coupling, for example in a spline pattern, in a second opposite circular direction.

[0086] For example, the junction 100J1 is configured as an X-junction. For example, in the X- junction one or more of the first filament end portions 100E1 face one or more of the second filament end portions divided apart from each other by the one or more of the filaments 100C1 , 100C2, 100C3 extending continuously through the junction. For example, the second layer is bonded to the first layer.

[0087] Fig. 11 is a block diagram for a method 5000 for manufacturing a crank 1000. For example, the method comprises forming 5100 one or more splined couplings 1110. For example, the method comprises forming 5200 one or more webs 1050. For example, the method comprises forming 5300 one or more beams 1010, 1020, 101 OX, 1020X. For example, the method comprises one or more of forming one or more of the beams bonded to one or more of the webs and forming one or more of the beams and bonding one or more of them to one or more of the webs.

[0088] For example, the forming one or more of the splined couplings 1110 comprises forming 5110 a first coupling fiber layer 210, for example comprising depositing 5111 one or more filaments 100 comprising fibers in a first path 210P1 forming a contour 210C1 comprising one or more splines 210S1, 210S2 matching a contour of one or more grooves 1510 of a splined coupling 1500 having a first axis of revolution Z1. For example, the forming 5110 a first coupling fiber layer comprises depositing 5112 one or more filaments 100 comprising fibers in a second path 210P2 that is concentric to the first path. For example, the forming one or more of the splined couplings comprises forming 5120 a second coupling fiber layer 220, for example by bonding one or more filaments 100 comprising fibers to the first coupling fiber layer. For example, the forming one or more of the splined couplings comprises forming 5130 a third coupling fiber layer 230 by bonding one or more filaments 100 comprising fibers to the second coupling fiber layer. For example, the forming the second coupling fiber layer comprisesdepositing 5123 one or more filaments in a third path 220P1 at least a portion of which is concentric with a sector 210AS of the first path and of the second path around the first axis Z1 .

[0089] In one sentence: the method 5000 for manufacturing the crank 1000 comprises: forming 5100 one or more of the splined couplings 1110, forming 5200 one or more of the webs 1050; and forming 5300 one or more of the beams 1010, 1020, 101 OX, 1020X bonded to one or more of the webs, wherein the forming one or more of the splined couplings 1110 comprises: forming 5110 a first coupling fiber layer 210 by depositing 5111 one or more filaments 100 comprising fibers in a first path 210P1 forming a contour 210C1 comprising one or more splines 210S1 , 210S2 matching a contour of one or more grooves 1510 of a splined coupling 1500 having a first axis of revolution Z1 , and depositing 5112 one or more filaments 100 comprising fibers in a second path 210P2 that is concentric to the first path; and forming 5120 a second coupling fiber layer 220 by bonding one or more filaments 100 comprising fibers to the first coupling fiber layer; and forming 5130 a third coupling fiber layer 230 by bonding one or more filaments 100 comprising fibers to the second coupling fiber layer, wherein the forming the second coupling fiber layer comprises depositing 5123 one or more filaments in a third path 220P1 at least a portion of which is concentric with a sector 210AS of the first path and of the second path around the first axis Z1.

[0090] For example, the depositing 5112 the second path comprises depositing one or more filaments 100 following and matching 5112M to a contour of the one or more filaments of the first path. For example, the forming 5120 the second coupling fiber layer 220 comprises depositing and bonding one or more filaments 100 onto the first path 210P1 and the second path 210P2 of the first coupling fiber layer 210. For example, one or more of the filaments are arranged to form 5125 an overpass 222 from the one or more filaments of the first path 210P1 on to the one or more filaments of the second path 210P2.

[0091] For example, the forming 5130 the third coupling fiber layer 230 comprises depositing 5400 one or more filaments 100 comprising fibers wherein paths of the filaments follow one or more of the first path 210P1 and the second path 210P2 of the first coupling fiber layer 210. For example, the first path 210P1 and the second path 210P2 of the first coupling fiber layer are stacked in a direction parallel to the first axis Z1 .

[0092] For example, the method comprises depositing 5126 one or more bonding joints 210J onto one or more of the splines 210S1 , 210S2 of the first coupling fiber layer 210. For example, a material comprised in the bonding joint has a fiber volume ratio that is lower than a fiber volume ratio of one or more of the filaments 100 comprised in one or more of the first coupling fiber layers and the third coupling fiber layers.

[0093] For example, the depositing 5123 of the third path 220P1 comprises depositing one or more filaments 100 comprising fibers in a circular arc over the sector 210AS. For example, the method comprises depositing 5111 the filament 100 in the first path 210P1 and continuing thedepositing 5410 as a spiral arrangement into the second path 210P2.

[0094] For example, the method comprises depositing 5400 one or more filaments 100 forming one or more of the paths 210P1, 210P2 in the first layer 210; and continuing the depositing by forming 5415 a layer-to-layer path 100LL one or more of into one or more paths 220P1 of the second layer 220 and out of one or more paths 220P1 of the second layer 220 into one or more of the paths 230P1 , 230P2 of the third layer 230.

[0095] For example, the method comprises depositing 5420 one or more polymer layers 215, 225 onto or more of the coupling fiber layers 210, 220, 230, wherein the polymer material comprised in the polymer layer has a fiber volume ratio that is lower than a fiber volume ratio of one or more of the filaments 100 comprised in one or more of the coupling fiber layers.

[0096] For example, the forming 5300 one or more beams 1010, 1020, 101 OX, 1020X comprises depositing 5400 one or more filaments 100 comprising fibers onto one or more of the webs 1050. For example, in the forming 5300, a longitudinal direction 1010D, 1020D, 1010XD, 1020XD of the filaments is extending towards one or more second couplings 1120 having a second axis of revolution Z2 that is offset from the first axis Z1. For example, the forming 5300 one or more beams 1010, 1020, 101 OX, 1020X comprises depositing 5400 the one or more filaments 100 from a first path spanning a first sector 210AS around the first axis Z1 to a second path spanning a second sector 410AS around the second axis Z2. For example, the forming 5300 one or more beams 1010, 1020, 101 OX, 1020X comprises depositing the one or more filaments 100 in a looping path, wherein the looping path one or more of: spans one or more first sectors 210AS around the first axis Z1 ; spans one or more second sectors 410AS around the second axis Z2; and comprises one or more segments 100S joining the first sector to the second sector.

[0097] For example, the forming 5300 one or more of the beams 1010, 1020, 101 OX, 1020X comprises bonding to the web 1050 one or more filaments 100 of the beams, the filaments having an orientation that is parallel to fibers at the bonding surface of the web. For example, the forming 5300 one or more of the beams 1010, 1020, 101 OX, 1020X comprises depositing 5400 onto the web 1050 one or more filaments 100 arranged with an orientation that is parallel to fibers at the bonding surface of the web.

[0098] For example, the forming 5100 one or more of the couplings 1110 comprises one or more of: forming 5400-0 an O-loop-comprising layer 210-L2, 220-L2, wherein a majority of the filaments 100 deposited in the looping paths are spanning the first sector in a first rotating direction around the first axis Z1 and the second sector in the first rotating direction around the second axis Z2; and forming 5400-S an S-loop-comprising layer 210-L1, 220-L1, wherein a majority of the filaments 100 deposited in the looping paths span the first sector in a first rotating direction around the first axis Z1 and spans the second sector in a second opposite rotating direction around the second axis Z2.

[0099] For example, the forming 5100 one or more of the couplings 1110 comprises forming 5500 a stack 500S of layers, comprising one or more of: forming 5501 a first end layer 501 of the stack of layers and forming 5502 a second end layer 502 of the stack of layers, each end layer comprising one or more of the O-loop-comprising layers 220-L2, each end layer joining a second coupling fiber layer 220; and forming 5510 a first layer 210-L1 and forming 5520 a second layer 210-L2, 220-L2 comprised between the first end layer of the stack of layers and the second end layer of the stack of layers. For example, the forming one or more of the first layer and the second layer comprises forming 5530 an interleave layout, comprising, by depositing of filaments 100: forming 5400-J a junction 100J1 , 100J2 of filaments comprised in the first layer, one or more filament end portions 100E1, 100E2, 100E3 meeting one or more filaments 100C1, 100C2, 100C3 extending continuously through the junction, and in the second layer, depositing 5400 one or more filaments 100C4, 100C5 parallel to the one or more filament end portions of the first layer and extending continuously over the end portions through the junction.

[0100] For example, forming the junction 100J1 comprises forming 5400-J an X-junction wherein one or more of the first filament end portions 100E1 face one or more of the second filament end portions 100E2 divided apart from each other by the one or more of the filaments 100C1, 100C2, 100C3 extending continuously through the junction. For example, forming 5400- J the X-junction comprises: depositing one or more of the filaments 100C1 , 100C2, 100C3 extending continuously through the junction; depositing one or more of the first filament end portions 100E1, wherein an extremity of the first filament end portion is within 3 widths from a first side of the filament extending continuously through the junction; and depositing one or more of the second filament end portions 100E2. For example, an extremity of the second filament end portion is facing the extremity of one or more of the first filament end portions and is within 3 widths from a second side of the filament extending continuously through the junction.

[0101] For example, one or more of the cranks 1001, 1002 are placed in a mold 8000 and subjected to a molding process 5700 comprising one or more of a stamping process, a compression molding process, and an overmolding process. For example, a first crank and a second crank are placed in the mold in a stack arrangement. For example, forming the stack arrangement comprises placing the web of the second crank against the web of the first crank. For example, the first crank and the second crank form a mirror arrangement.

[0102] Referring, for example, to Figs. 10A to 10C and to Fig. 11 , the method 5000 for manufacturing a crank 1000, for example a hollow crank 1005, comprises forming 5600 a first crank shell 1006 and forming a second crank shell 1007. For example, the forming each of the crank shells comprises one or more of: the forming 5100 one or more of the splined couplings 1110; the forming 5200 one or more of the webs 1050; and the forming 5300 one or more of thebeams 1010, 1020. For example, the method further comprises one or more of forming a stack arrangement comprising the first shell and the second shell, and bonding the first shell to the second shell. For example, one or more of the beams of the first crank shell are bonded to one or more of the beams of the second crank shell. For example, one or more of the crank shells are preforms formed using the system 2000 for manufacturing preforms.

[0103] For example, the crank shells 1006, 1007 one or more of comprise and at least partially enclose, for example in one or more of a sandwich and Russian dolls assembly, one or more subshells 1006S1 , 1006S2, 1006S3, 1007S1 , 1007S2, 1007S3. For example, one or more of the subshells comprise one or more of beams, splined couplings, and webs comprising, for example, one or more of filaments 100, polymer, profiled rods, fiber-comprising chips, and bulk molding compound.

[0104] The method 5000 for manufacturing the crank 1000, for example the hollow crank, comprises: forming 5600 a first crank shell 1006 and forming a second crank shell 1007, the forming each of the crank shells comprising: the forming 5100 one or more of the splined couplings 1110; the forming 5200 one or more of the webs 1050; and the forming 5300 one or more of the beams 1010, 1020, forming a stack arrangement comprising the first shell and the second shell, and bonding the first shell to the second shell, wherein one or more of the beams of the first crank shell are bonded to one or more of the beams of the second crank shell.

[0105] For example, the method further comprises bonding one or more U-shaped profiles 1060 against one or more seams 1070 where the first crank 1001, 1006 meets the second crank 1002, 1007. For example, one or more of the crank shells 1006, 1007, the subshells 1006S1, 1006S2, 1006S3, 1007S1 , 1007S2, 1007S3, and the U-shaped profiles 1060 are formed by one or more of: depositing filaments 100, for example using the filament deposition system 2100; depositing one or more profiled rods; depositing one or more of fiber-comprising chips and bulk molding compound, for example into a mold; and one or more of pressing, stamping, compression molding, and overmolding, for example within a mold.

[0106] For example, a filament comprises one or more of a tow, a roving, a tape, a roving or tape comprising one or more folds along its longitudinal extent, a commingled yarn, or a combination thereof. For example the combination is in one or more of: i) a parallel arrangement; and ii) a sequential arrangement along the longitudinal direction of the filament. For example, the filament comprises one or more thermoplastic resins. For example, the filament is preimpregnated with one or more thermoplastic resin. For a further example, the filament is impregnated with one or more thermoplastic resins within 10 minutes prior to or upon deposition of the filament onto a substrate 200. For example, the filament comprises one or more of: a plurality of continuous fibers, a plurality of discontinuous fibers, and a plurality of chopped fibers.

[0107] For example, a filament comprising a plurality of discontinuous fibers comprises one ormore sets of discontinuous fibers arranged as a plurality of parallel fibers. For example, the fibers in a filament comprising discontinuous fibers have a uniform length. For example, the discontinuous fibers have a length comprised in a range from 2 mm to 20 mm, for example from 2 mm to 10 mm, for example from 3 mm to 8 mm, for example from 3 mm to 6 mm. For example, the length-to-diameter ratio of a discontinuous fiber is in a range from 500 to 1500, for example from 600 to 1200. For example, a fiber having a length that is greater than that of a discontinuous fiber is a continuous fiber. For example, a fiber having a length that is less than that of a discontinuous fiber is a chopped fiber. For example, the discontinuous fibers are arranged parallel to the longitudinal direction of the filament. For example, at least 50%, for example more than 75%, for example more than 90%, for example more than 95% of the fibers are parallel to the longitudinal direction of the filament, for example within 15° of the longitudinal direction of the filament, for example within 10°, for example within 5°.

[0108] For example, the width of the tow or filament 100 is comprised in a range from 0.2 mm to 10 mm, for example from 0.4 mm to 5 mm, for example from 0.4 mm to 3 mm, for example from 0.4 mm to 2 mm, for example from 0.4 mm to 1 mm, for example from 0.45 mm to 0.6 mm. For example, a tape is formed by cutting a sheet or a web comprising a plurality of fibers in a direction parallel to the fibers. For example, a filament, for example a tape, has a width in a range from 0.4 mm to 3 mm, for example from 0.6 mm to 2 mm, for example from 0.8 mm to 1.5 mm, for example from 0.9 mm to 1.2 mm.

[0109] For example, a filament comprises one or more fiber materials, for example selected from one or more of: a carbon fiber, a glass fiber, an aramid fiber, a basalt fiber, a metal fiber, and a natural fiber. For example, a natural fiber comprises fiber extracted from one or more of: a sisal, a flax, a ramie, a cotton, a banana, a hemp, and a byssus. For example, a set of continuous fibers or a set of discontinuous fibers comprises fibers of one or more of the fiber materials.

[0110] For example, the thermoplastic polymer material comprises one or more filler materials selected from the group comprising: short fibers, discontinuous fiber, chopped fibers, recycled fibers, microspheres, and nanofillers.

[0111] For example, a layer comprises one or more of: filaments comprising one or more fibers, for example a tape comprising unidirectional fibers one or more of impregnated with a thermoplastic material and sliced along the direction of the fibers of the tape; for another example rods, for example profiled rods, for example profiled by an extruder, for example an extruder comprising an extruding nozzle, for example wherein the entirety of the nozzle’s internal periphery exerts a profiling force onto the material being extruded; a filler material, for example a bulk molding compound, for example comprising fibers, for example chopped fibers; and one or more organosheets, for example comprising a thermoplastic material.

[0112] Fig. 12 is a side view of a system 2000 for manufacturing preforms 1001, 1002, 1006,1007, 1060. For example, the system 2000 for manufacturing preforms comprises a filament or tow depositing system 2100. For example, the system 2000 for manufacturing preforms further comprises a polymer deposition head 2002, for example comprising an extruder 2002E. For example, the filament depositing system is a robotic system for depositing the filament or tow 100 for example an elongate fiber tow. For example, the system 2000 comprises a slide head 2800 comprising one or more axes 2810, 2820. For example, the slide head 2800 comprises a first axis 2810 that is orthogonal to a second axis 2820. For example, the slide head 2800 is connected to a tow deposition head 2100. For example, a method for depositing a tow 100, for example using the tow deposition head 2100, comprises depositing one or more tows 100, for example a section of an elongate fiber tow, onto a supporting surface, for example the substrate or build plate 200. For example, the tow deposition head 2100 moves, for example translates, in one or more directions with respect to the substrate or build plate 200. A method for forming one or more of the preforms or parts comprises rotating the shoe 2101 connected to a rotating support 2102, for example rotating around a rotating axis 1130MPZ, for example parallel to the Z-axis. For example, one or more of the axes 2810, 2820 is intersected by the Z-wise extension of the rotating axis 1130MPZ.

[0113] For example, the system 2000 for depositing a filament or tow 100 comprises a computer system 4000, for example to control the tow deposition head 2100. For example, the computer system 4000 generates or receives, for example from one or more of a computer network and a non-transitory computer-readable storage medium (NTCRSM) 4120, instructions to form one or more of the parts or preforms and depositing one or more of the filaments 100. For example, the NTCRSM comprises instructions for one or more of: orienting the shoe 2101 into one or more directions with respect to the direction at which the tow deposition head 2100 advances with respect to the substrate 200; rotating the shoe 2101 during deposition of the filament or tow 100, for example simultaneously to advancing the shoe with respect to the substrate 200, for example as a function of the radius of curvature of the path of the tow being deposited; dispensing filament or tow 100 at one or more rates, for example as a function of one or more of the speed at which the shoe 2101 is advancing with respect to the substrate 200, the radius of curvature of the path of the tow being deposited, the orientation of the shoe with respect to the direction at which the tow deposition head 2100 advances, and the rotating speed of the shoe.

[0114] For example, the present disclosure further relates to a method for forming a composite device wherein a first part is bonded to a second part using a method of electric resistance welding wherein a current is passed into one or more electrically-conductive tows 110. For example, the method comprises depositing an electrically-conductive tow 110, for example comprising a thermoplastic material, for example using the tow deposition apparatus 2000. The method for forming the composite device comprises, for example, depositing an electrically-conductive tow or filament 110 comprising one or more electrically-conductive fibers 100EF, for example a plurality of electrically-conductive fibers 100EF. For example, a path 150 of the tow comprises one or more curves. For example, the depositing comprises, for example, rotating the rotatable shoe 2101 of the tow deposition apparatus 2000 for guiding the tow along the curves of the path.

[0115] For example, a filament or tow 100, 110 comprises an adhesive material, for example a thermoplastic adhesive. For example, a thermoplastic adhesive comprises one or more of: a polyaryletherketone (PAEK), a polyether ether ketone (PEEK), a polyetherketoneketone (PEKK), a polyetherimide (PEI), an acrylonitrile butadiene styrene (ABS), a nylon, a polybutylene terephthalate (PBT), a polycarbonate (PC), a polycarbonate-ABS (PC-ABS), a polyether sulfone (PES), a polyethylene (PE), a polyamide (PA), a polyimide (PI), a polyethylene terephthalate (PET), a polyphenylene sulfide (PPS), a polyphenylsulfone (PPSLI), a polyphosphoric acid (PPA), a polypropylene (PP), a polysulfone (PSU), a polyurethane (Pll), and a polyvinyl chloride (PVC). For example, a thermoplastic further comprises a filler, for example a filler comprising a plurality of microspheres. For a further example, the electrically- conductive tow 110 is one or more of pre-impregnated and impregnated by an electrically- conductive thermoplastic resin.

[0116] For example, the filament has a fiber volume fraction in a range from 0.1 to 0.9, for example from 0.3 to 0.9, for example from 0.4 to 0.85, for example from 0.5 to 0.85, for example from 0.55 to 0.82.

[0117] For example, the electrically-conductive tow 110 is embedded into a layer comprising one or more of: tows; electrically insulating and thermoplastic-rich tows or filaments; and adhesive resins or compounds, for example thermoplastic resins or compounds.

[0118] For example, in the method for forming a composite device, bonding the first part to a second part comprises, for example, placing a second part, for example aligning the second part with the first part, for contacting one or more of the first part and the electrically-conductive tow for bonding. For example, the placing the second part is against a surface of the first part that is closest to the electrically-conductive tow. For example, the contacting comprises pressing, for example pressing the second part against the first part.

[0119] Although illustrations depict the electrically-conductive tows 110 against or within a layer at the surface of a part, an alternative or combinable arrangement comprises one or more electrically-conductive tows embedded within one or more layers that are comprised one or more layers beneath a surface of the part, the layers comprising, for example, one or more of: a thermoplastic material; a metal, for example configured as a foil; and a thermal insulator, for example configured as a foil or a sheet. For example, the metal is electrically isolated from the electrically-conductive tows by one or more of an insulating material and a layer comprising a thermoplastic material. For example, assuming a layer has a thickness of an electrically-conductive tow 110, an electrically-conductive tow used for melting a thermoplastic material is arranged to a practical maximum of 20 layers beneath the bonding surface, for example from 0 to 10 layers, for example from 0 to 5 layers, for example from 0 to 3 layers beneath the bonding surface. For example, the layers are electrically isolating, for example comprising one or more thermoplastic-rich paths or materials. For example, assuming a layer has a thickness of an electrically-conductive tow 110 in a range from 0.05 mm to 0.4 mm, a practical maximum of 20 layers beneath the bonding surface is in a range from 1 mm to 8 mm. For example, a bonding process is limited by a maximum temperature to avoid degradation of the thermoplastic material and a process duration, for example to limit heat diffusion within a part to a point wherein structural components are deformed beyond a desired scope, for example beyond a bonding region or a region targeted for deformation, due to reaching one or more of a glass transition temperature and a melting temperature.

[0120] Fig. 14 is a perspective view of a crank 1070, for example the bicycle crank 1000. For example, a version of the crank, for example having an aspect ratio different from that represented, is usable as an arm comprised on a multicopter. For example, the crank comprises components, for example lids 1070L1 , 1070L2, that are, in a method for bonding, bonded to the crank by supplying electrical power to one or more electrically-conductive tows 110. For example, one or more of the crank 1070 and the lids 1070L1 , 1070L2 comprise one or more electrically-conductive tows. For example, one or more of the crank 1070 and the lids 1070-L1, 1070L2 comprise a thermoplastic material facing, upon applying the lid against the crank, one or more of the electrically-conductive tows. For example, one or more of the crank and the lids are manufactured by a robotic system 2000 for depositing a filament, a tow, for example in successive layers. For example, one or more of the crank and the lids are, in a first step, each manufactured by a robotic system, for example one or more of the robotic system 2000 and a pick-and-place system, for example to deposit or assemble profiled rods. For a further example, one or more of the lids comprises an organosheet, for example comprising a thermoplastic material, for example a thermoplastic fiber-reinforced laminate. For example, one or more of the crank, for example as a first part, and the lids, for example as second parts, are, in a second step, each subjected to one or more of pressing, stamping, molding, and compression molding, for example inside one or more molds.

[0121] For example, the thermoplastic material is comprised in one or more of: one or more electrically-conductive tows; one or more thermoplastic-rich paths or blobs; one or more thermoplastic foils; one or more thermoplastic coatings; and one or more thermoplastic powders. For example, the method for bonding comprises pressing one or more of the lids 1070L1, 1070L2, for example one or more portions of the lids, against the crank. For example, the method for bonding comprises heating one or more of the crank and the lids, for example to a temperature lower than a melting temperature of one or more of the crank and the lids.

[0122] Although Fig. 14 presents an electrically-conductive tow 110 comprised in each of the lids 1070L1 , 1070L2, in a further example, one or more electrically-conductive tows are comprised at one or more of the surface, embedded in a surface layer, and embedded beneath a surface layer of one or more of the crank 1070 and one or more of the lids 1070L1 , 1070L2.

[0123] Fig. 15A is a top view of the bicycle crank 1070 onto which a foldable reinforcement plate 1070L3 is about to be folded. For example, the plate 1070L3 comprises one or more electrically-conductive tows 110. For example, the plate comprises materials as those comprised in the lids 1070L1, 1070L2. For example, a method of forming the plate comprises steps as those described for forming one or more of the lids, the first part 1000, and the second part 1005. For example, the plate comprises, for example as visually segmented in Fig. 10 by dashed folding lines 1070FL, one or more flaps 1070F1 , 1070F2, 1070F3. For example, for forming a wrapping around an axis of the crank, the plate comprises, for example sequentially, a first flap 1070F1 , a first lid surface 1070LS1, a second flap 1070F2, a second lid surface 1070LS2, and a third flap 1070F3. For example, the plate 1070L3 comprises one or more electrically-conductive tows. Fig. 15A illustrates how, for example, a single electrically- conductive tow is arranged to span the entire plate, extending from the first flap, through the lid surfaces, and ending onto the third flap. For example, the electrically-conductive tow extends on one or more of the flaps and the lids along one or more of: one or more contours; one or more inner surfaces; one or more portions facing or contacting surfaces of the crank; and one or more folding lines. For example, a path 110PF of the electrically-conductive tow across a folding line forms an angle that is equal to or less than 90° with respect to an average path direction running along a folding line, for example in a range from 60° to 30° with respect to the folding line. For example, the electrically-conductive tow comprises ends 110E1, 110E2 extending beyond an external contour of the plate, for example for connecting to a power supply source. For example, the ends are cut after bonding the plate to the crank. For example, one or more of the electrically-conductive tows are arranged one or more of against one or more of the faces of the plate and within the thickness of the plate, for example beneath one or more layers of material, for example thermoplastic material, comprised in the plate.

[0124] For example, a method for forming a wrapping around a part, for example the bicycle crank 1070, comprises one or more of: i) supplying electrical power to one or more of the electrically-conductive tows 110, for example raising a temperature along one or more folding lines 1070FL to a temperature greater than a glass transition temperature of a thermoplastic material comprised along the folding line; ii) forming one or more folds by applying a load against one or more of the plate and the crank for deforming the plate, for example against one or more of a face and an angle of the crank, for example against a die, for example against a sheet bending device; iii) closing the wrapping, for example by folding the third flap against the first flap; and iv) supplying further electrical power to one or more of the electrically-conductivetows 110, for example raising a temperature of one or more of the tows and thermoplastic materials along the tows to a melting temperature, for example for bonding the plate to the crank. For example, the method for forming the wrapping further comprises heating one or more of the plate and the crank, for example in one or more of a press and a mold, for another example, by irradiating one or more of the plate and the crank with infrared energy, for example using a laser. For example, the method for forming the wrapping comprises pressing one or more of the flaps, the folds, and the lid surfaces against the crank.

[0125] Fig. 10B is a cross-section of the bicycle crank 1070 and of the foldable reinforcement plate 1070L3. For example, the plate 1070L3 comprises one or more grooves 1070G, for example formed along one or more of the folding lines 1070FL. For example, forming the grooves comprises depositing fewer layers of material, for example of material comprising a thermoplastic, along the groove compared to the locations comprising one or more of the flaps and the lid surfaces. For another example, forming the grooves comprises one or more of pressing using a die, cutting away, and eroding material of the plate. For example, forming the grooves comprises heating the plate, for example along the folding lines.

[0126] For example, the method for one or more of folding and bonding a foldable reinforcement plate 1070L3 is applicable to one or more of folding and bonding a skin to a structure, for example to the hollow crank assembly 1000H of Fig. 10, for example for one or more of forming, bending, and bonding one or more of the U-shaped profiles 1060. For a further example, the plate 1070L3 is one or more of deformed and bonded as a wrapping around the hollow crank assembly 1000H, for example as a replacement of or a supplement to the U- shaped profiles 1060.

Claims

CLAIMS1. A coupling (1110) comprising: a first coupling fiber layer (210) and a third coupling fiber layer (230), each layer comprising one or more filaments (100) comprising fibers, the filaments being arranged in a first path (210P1) forming a contour (210C1) comprising one or more splines (210S1 , 210S2) matching a contour of one or more grooves (1510) of a splined coupling (1500) having a first axis of revolution (Z1), and a second path (210P2) that is concentric to the first path; and a second coupling fiber layer (220), comprised between the first coupling fiber layer and the third coupling fiber layer and comprising one or more filaments (100) comprising fibers, wherein one or more of the filaments of the second coupling fiber layer are arranged in a third path (220P1) at least a portion of which is concentric with a sector (210AS) of the first path and of the second path around the first axis (Z1).

2. The coupling according to claim 1 , wherein the one or more filaments (100) of the second path (210P2) are comprised in the same layer (210, 230) as the one or more filaments of the first path (210P1) and one or more of matching with and bonded to a contour of the one or more filaments of the first path.

3. The coupling according to any one of the preceding claims, wherein one or more of the filaments of the second coupling fiber layer (220) are forming an overpass (222) and bonded to the one or more filaments of the first path (210P1) and of the second path (210P2).

4. The coupling according to any one of the preceding claims, wherein one or more of the splines (210S1, 210S2) of the first coupling fiber layer (210) and one or more of the splines (230S1 , 230S2) of the third coupling fiber layer (230) are stacked in a direction parallel to the first axis (Z1).

5. The coupling according to any one of the preceding claims, further comprising one or more bonding joints (210J) from one or more of the splines (210S1 , 210S2) of the first coupling fiber layer (210) to one or more of the splines (230S1 , 230S2) of the third coupling fiber layer (230), wherein a material comprised in the bonding joint has a fiber volume ratio that is lower than a fiber volume ratio of one or more of the filaments (100) comprised in one or more of the first coupling fiber layers and the third coupling fiber layers.

6. The coupling according to any one of the preceding claims, wherein the third path (220P1) is arranged as a circular arc over the sector (210AS).

7. The coupling according to any one of the preceding claims, wherein a filament (100) comprised in the first path (210P1) continues as a spiral arrangement into the second path (210P2).

8. The coupling according to any one of the preceding claims, wherein one or more filaments (100) comprised in one or more of the paths (210P1, 210P2, 230P1 , 230P2) comprised inone or more of the first layer (210) and the third layer (230) comprise a continuous layer-to- layer path (100LL) one or more of into and out of one or more paths (220P1) of the second layer (220).

9. The coupling according to any one of the preceding claims, further comprising one or more polymer layers (215, 225) comprised between two or more coupling fiber layers (210, 220, 230), wherein the polymer material comprised in the polymer layer has a fiber volume ratio that is lower than a fiber volume ratio of one or more of the filaments (100) comprised in one or more of the coupling fiber layers.

10. The coupling according to any one of the preceding claims, wherein the coupling (1110) further comprises one or more beams (1010, 1020, 101 OX, 1020X) comprising one or more filaments (100) comprising fibers, a longitudinal direction (1010D, 1020D, 1010XD, 1020XD) of the filaments extending towards one or more second couplings (1120) having a second axis of revolution (Z2) that is offset from the first axis (Z1).

11. The coupling according to claim 10, wherein one or more of the filaments (100) extend from from a first path spanning a first sector (210AS) around the first axis (Z1) to a second path spanning a second sector (410AS) around the second axis (Z2).

12. The coupling according to claim 10, wherein one or more of the beams (1010, 1020, 101 OX, 1020X) comprise one or more filaments (100L) arranged in a looping path, wherein the looping path: spans one or more first sectors (210AS) around the first axis (Z1); spans one or more second sectors (410AS) around the second axis (Z2); and comprises one or more segments (100S) joining the first sector to the second sector.

13. The coupling according to any one of claims 10 to 12, further comprising a web (1050, 1051 , 1052) bonded to one or more of the beams (1010, 1020, 101 OX, 1020X).

14. The coupling according to claim 13, wherein one or more of the faces (1050F1 , 1050F2) of the web (1050) comprises filaments (100) that are bonded to one or more of the beams, the filaments having an orientation that is parallel to fibers comprised at the bonding surface of one or more of the beams (1010, 1020, 101 OX, 1020X).

15. The coupling according to claim 12, further comprising: an O-loop-comprising layer (210-L2, 220-L2), wherein a majority of the looping paths are spanning the first sector in a first rotating direction around the first axis (Z1) and the second sector in the first rotating direction around the second axis (Z2); and an S-loop-comprising layer (210-L1 , 220-L1), wherein a majority of the looping paths span the first sector in a first rotating direction around the first axis (Z1) and spans the second sector in a second opposite rotating direction around the second axis (Z2).

16. The coupling according to claim 15, wherein the coupling (1110) comprises a stack (500S) of layers, whereina first end (501) of the stack of layers and a second end (502) of the stack of layers each comprise one or more of the O-loop-comprising layers (220-L2), each joining a second coupling fiber layer (220); and a first layer (210-L1) and a second layer (210-L2, 220-L2) comprised between the first end of the stack of layers and the second end of the stack of layers comprising an interleave layout, wherein in the interleave layout: at a junction (100J1 , 100J2) of filaments comprised in the first layer, one or more filament end portions (100E1 , 100E2, 100E3) meet one or more filaments (100C1, 100C2, 100C3) extending continuously through the junction, and in the second layer, one or more filaments (100C4, 100C5) are arranged parallel to the one or more filament end portions of the first layer and extend continuously over the end portions through the junction.

17. The coupling according to claim 16, wherein the junction (100J1) is configured as an X- junction wherein one or more of the first filament end portions (100E1) face one or more of the second filament end portions divided apart from each other by the one or more of the filaments (100C1, 100C2, 100C3) extending continuously through the junction.

18. The coupling according to any one of claims 16 to 17, wherein the second layer is bonded to the first layer.

19. The coupling according to any one of the preceding claims, wherein the filament (100) comprises continuous fibers.

20. A crank (1000, 1001, 1002) comprising one or more splined couplings (1110) according to any one of claims 1 to 19, wherein the crank comprises one or more webs (1050, 1051 , 1052) extending from one or more of the couplings in a web plane set at an orientation comprised in a range from -30° to +30° with respect to a plane orthogonal to the first axis (Z1) of the coupling.

21. The crank according to claim 20, wherein a first face (1051 F1) of the web (1050) and an opposite second face (1050F2) of the web each comprise one or more beams (1010, 1020, 101 OX, 1020X) bonded to the web and comprising one or more filaments (100) comprising fibers, a longitudinal direction (1010D, 1020D, 1010XD, 1020XD) of the filaments extending towards one or more second couplings (1120) having a second axis of revolution (Z2) that is offset from the first axis (Z1).

22. The crank according to claim 21 , wherein a second layout (1010LO2) of the one or more beams (1010, 1020, 101 OX, 1020X) arranged against the second face (1050F2) of the web (1050) is a web-surface-based mirror of a first layout (1010LO1) of the one or more beams arranged against the first face (1050F1) of the web.

23. The crank according to claim 22, comprising a first layup (200111) comprising one or more layers (1010L1 , 1010L2, 1010L3) comprisingone or more of the filaments (100) comprising fibers, the layers being stacked in a first direction (Z) extending away from the first face (1050F1) of the web (1050), and a second layup (200LI2) comprising one or more layers (1010L1 , 1010L2, 1010L3) comprising one or more of the filaments (100) comprising fibers, the layers being stacked in a second direction (-Z) extending away from the second face (1050F2) of the web (1050), wherein the second layup is a web-surface-based mirror of the first layup.

24. The crank according to any one of claims 21 to 23, wherein the web (1050) comprises one or more layers comprising one or more filaments (100) comprising fibers, wherein one or more of the layers at one or more of the faces (1050F 1 , 1050F2) of the web comprise one or more filaments (100) having an orientation that is parallel to one or more of the fibers at a surface of one or more of the beams (1010, 1020, 101 OX, 1020X) bonded to the web.

25. The crank according to any one of claims 20 to 24, comprising: a first layer (1050L1) at a face (1050F1) of the web (1050), comprising a first plurality of parallel filaments (100) oriented at a first orientation (1050A1) comprised in a range from 1° to 60° with respect to a longitudinal direction (X1) from a first coupling to a second coupling; a second layer (1050L2), bonded to the first layer, comprising a second plurality of parallel filaments oriented at a second orientation (1050A2) comprised in a range from -5° to +5° with respect to the longitudinal direction; and a third layer (1050L3), bonded to the second layer, comprising a plurality of parallel filaments oriented at a third orientation (1050A3) that is within a range from -5° to +5° from a mirror orientation of the first orientation with respect to the longitudinal direction.

26. The crank according to any one of claims 20 to 25, wherein the one or more webs (1050) comprise the one or more beams (1010, 1020, 101 OX, 1020X) on a first face (1050F1) of the web and on a second face (1050F2) of the web.

27. The crank according to any one of claims 20 to 25, wherein the one or more beams (1010,1020, 101 OX, 1020X) are comprised between a first of the webs (1051) and a second of the webs (1052).

28. The crank according to any one of claims 20 to 27, further comprising one or more hollow inserts (1210) within one or more of the couplings and axially aligned with the axis (Z1 , Z2) of the coupling (1110, 1120).

29. The crank according to any one of claims 20 to 28, further comprising one or more of a hollow screw and a hollow nut (1220) inserted through one or more of the couplings and axially aligned with the axis (Z1 , Z2) of the coupling (1110, 1120).

30. A method (5000) for manufacturing a crank (1000) according to any one of claims 20 to 29, comprising: forming (5100) one or more splined couplings (1110) according to any one of claims 1 to 19, forming (5200) one or more webs (1050); andforming (5300) one or more beams (1010, 1020, 101 OX, 1020X) bonded to one or more of the webs, wherein the forming one or more of the splined couplings (1110) comprises: forming (5110) a first coupling fiber layer (210) by depositing (5111) one or more filaments (100) comprising fibers in a first path (210P1) forming a contour (210C1) comprising one or more splines (210S1, 210S2) matching a contour of one or more grooves (1510) of a splined coupling (1500) having a first axis of revolution (Z1), and depositing (5112) one or more filaments (100) comprising fibers in a second path (210P2) that is concentric to the first path; and forming (5120) a second coupling fiber layer (220) by bonding one or more filaments (100) comprising fibers to the first coupling fiber layer; and forming (5130) a third coupling fiber layer (230) by bonding one or more filaments (100) comprising fibers to the second coupling fiber layer, wherein the forming the second coupling fiber layer comprises depositing (5123) one or more filaments in a third path (220P1) at least a portion of which is concentric with a sector (210AS) of the first path and of the second path around the first axis (Z1).

31. The method of claim 30, wherein the depositing (5112) the second path comprises depositing one or more filaments (100) following and matching (5112M) to a contour of the one or more filaments of the first path.

32. The method according to any one of claims 30 to 31 , wherein the forming (5120) the second coupling fiber layer (220) comprises depositing and bonding one or more filaments (100) onto the first path (210P1) and the second path (210P2) of the first coupling fiber layer (210), wherein one or more of the filaments are arranged to form (5125) an overpass (222) from the one or more filaments of the first path (210P1) on to the one or more filaments of the second path (210P2).

33. The method according to any one of claims 30 to 32, wherein the forming (5130) the third coupling fiber layer (230) comprises depositing (5400) one or more filaments (100) comprising fibers wherein paths of the filaments follow one or more of the first path (210P1) and the second path (210P2) of the first coupling fiber layer (210) and are stacked in a direction parallel to the first axis (Z1).

34. The method according to any one of claims 30 to 33, further comprising depositing (5126) one or more bonding joints (210J) onto one or more of the splines (210S1 , 210S2) of the first coupling fiber layer (210), wherein a material comprised in the bonding joint has a fiber volume ratio that is lower than a fiber volume ratio of one or more of the filaments (100) comprised in one or more of the first coupling fiber layers and the third coupling fiber layers.

35. The method according to any one of claims 30 to 34, wherein the depositing (5123) of thethird path (220P1) comprises depositing one or more filaments (100) comprising fibers in a circular arc over the sector (210AS).

36. The method according to any one of claims 30 to 35, comprising depositing (5111) a filament (100) in the first path (210P1) and continuing the depositing (5410) as a spiral arrangement into the second path (210P2).

37. The method according to any one of claims 30 to 36, comprising: depositing (5400) one or more filaments (100) forming one or more of the paths (210P1, 210P2) in the first layer (210); and continuing the depositing by forming (5415) a layer-to-layer path (100LL) one or more of into one or more paths (220P1) of the second layer (220) and out of one or more paths (220P1) of the second layer (220) into one or more of the paths (230P1 , 230P2) of the third layer (230).

38. The method according to any one of claims 30 to 37, further comprising depositing (5420) one or more polymer layers (215, 225) onto or more of the coupling fiber layers (210, 220, 230), wherein the polymer material comprised in the polymer layer has a fiber volume ratio that is lower than a fiber volume ratio of one or more of the filaments (100) comprised in one or more of the coupling fiber layers.

39. The method according to any one of claims 30 to 38, wherein the forming (5300) one or more beams (1010, 1020, 101 OX, 1020X) comprises depositing (5400) one or more filaments (100) comprising fibers onto one or more of the webs (1050), a longitudinal direction (1010D, 1020D, 1010XD, 1020XD) of the filaments extending towards one or more second couplings (1120) having a second axis of revolution (Z2) that is offset from the first axis (Z1).

40. The method according to claim 39, wherein the forming (5300) one or more beams (1010, 1020, 101 OX, 1020X) comprises depositing (5400) the one or more filaments (100) from a first path spanning a first sector (210AS) around the first axis (Z1) to a second path spanning a second sector (410AS) around the second axis (Z2).

41. The method according to claim 39, wherein the forming (5300) one or more beams (1010, 1020, 101 OX, 1020X) comprises depositing the one or more filaments (100) in a looping path, wherein the looping path one or more of: spans one or more first sectors (210AS) around the first axis (Z1); spans one or more second sectors (410AS) around the second axis (Z2); and comprises one or more segments (100S) joining the first sector to the second sector.

42. The method according to any one of claims 39 to 41 , wherein the forming (5300) one or more of the beams (1010, 1020, 101 OX, 1020X) comprises bonding to the web (1050) one or more filaments (100) of the beams, the filaments having an orientation that is parallel to fibers at the bonding surface of the web.

43. The method according to any one of claims 39 to 42, wherein the forming (5300) one or more of the beams (1010, 1020, 101 OX, 1020X) comprises depositing (5400) onto the web (1050) one or more filaments (100) arranged with an orientation that is parallel to fibers at the bonding surface of the web.

44. The method according to any one of claims 41 to 43, wherein forming (5100) one or more of the couplings (1110) comprises: forming (5400-0) an O-loop-comprising layer (210-L2, 220-L2), wherein a majority of the filaments (100) deposited in the looping paths are spanning the first sector in a first rotating direction around the first axis (Z1) and the second sector in the first rotating direction around the second axis (Z2); and forming (5400-S) an S-loop-comprising layer (210-L1 , 220-L1), wherein a majority of the filaments (100) deposited in the looping paths span the first sector in a first rotating direction around the first axis (Z1) and spans the second sector in a second opposite rotating direction around the second axis (Z2).

45. The method according to claim 44, wherein forming (5100) one or more of the couplings (1110) comprises forming (5500) a stack (500S) of layers, comprising: forming (5501) a first end layer (501) of the stack of layers and forming (5502) a second end layer (502) of the stack of layers, each end layer comprising one or more of the O-loop- comprising layers (220-L2), each end layer joining a second coupling fiber layer (220); and forming (5510) a first layer (210-L1) and forming (5520) a second layer (210-L2, 220-L2) comprised between the first end layer of the stack of layers and the second end layer of the stack of layers, wherein the forming the first layer and the second layer comprises forming (5530) an interleave layout, comprising, by depositing of filaments (100): forming (5400-J) a junction (100J1 , 100J2) of filaments comprised in the first layer, one or more filament end portions (100E1, 100E2, 100E3) meeting one or more filaments (100C1, 100C2, 100C3) extending continuously through the junction, and in the second layer, depositing (5400) one or more filaments (100C4, 100C5) parallel to the one or more filament end portions of the first layer and extending continuously over the end portions through the junction.

46. The method according to claim 45, wherein forming the junction (100J1) comprises forming (5400-J) an X-junction wherein one or more of the first filament end portions (100E1) face one or more of the second filament end portions (100E2) divided apart from each other by the one or more of the filaments (100C1, 100C2, 100C3) extending continuously through the junction.

47. The method according to claim 46, wherein forming (5400-J) the X-junction comprises: depositing one or more of the filaments (100C1, 100C2, 100C3) extending continuously through the junction;depositing one or more of the first filament end portions (100E1), wherein an extremity of the first filament end portion is within 3 widths from a first side of the filament extending continuously through the junction; and depositing one or more of the second filament end portions (100E2), wherein an extremity of the second filament end portion is facing the extremity of one or more of the first filament end portions and is within 3 widths from a second side of the filament extending continuously through the junction.

48. The method according to any one of claims 30 to 47, wherein one or more of the cranks (1001, 1002) are placed in a mold (8000) and subjected to a molding process (5700) comprising one or more of a stamping process, a compression molding process, and an overmolding process.

49. The method according to claim 48, wherein a first crank and a second crank are placed in the mold (8000) in a stack arrangement.

50. The method according to claim 49, wherein forming the stack arrangement comprises placing the web of the second crank against the web of the first crank.

51. The method according to claim 50, wherein the first crank and the second crank form a mirror arrangement.

52. The method according to any one of claims 30 to 51 , comprising: forming (5600) a first crank shell (1006) and forming a second crank shell (1007), the forming each of the crank shells comprising: the forming (5100) one or more of the splined couplings (1110); the forming (5200) one or more of the webs (1050); and the forming (5300) one or more of the beams (1010, 1020), forming a stack arrangement comprising the first shell and the second shell, and bonding the first shell to the second shell, wherein one or more of the beams of the first crank shell are bonded to one or more of the beams of the second crank shell.

53. The method according to any one of claims 49 to 52, further comprising bonding one or more U-shaped profiles (1060) against one or more seams (1070) where the first crank (1001, 1006) meets the second crank (1002, 1007).

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