CONTINUOUS ORGANIC FIBER REINFORCED 3D PRINTING FILM PRODUCTION SYSTEM AND METHOD
Patent Information
- Authority / Receiving Office
- TR · TR
- Patent Type
- Applications
- Current Assignee / Owner
- KOCAELI UNIVERSITESI
- Filing Date
- 2026-03-16
- Publication Date
- 2026-06-22
Abstract
Description
1 TARIFF CONTINUOUS ORGANIC FIBER REINFORCED 3D PRINTING FILM PRODUCTION SYSTEM AND METHOD Technical Area The invention describes the on-line melting of flexible continuous organic fibers in a thermoplastic matrix. It can be wetted and calibrated, its diameter is kept under closed-loop control, and it can be wound onto a reel. With a standard-sized composite 3D printing filament production system, this filament can be produced in many ways. The line includes an inlet heater block, in-line diameter measurement, and feedback pull / wind stations. It relates to the production method used in its manufacture. The invention specifically relates to FFF (Fused Filament Fabrication) / FDM (Fused Deposition Modeling) 10 unreinforced or short fiber / particle printing is common in the market for 3D printing applications based on this technology. the limited mechanical performance of filled filaments and existing continuous fiber solutions to overcome the limitation of being limited only to the in-part orientation approach during printing. It is related to an innovative production system and method aimed at organic production. The equipment in question is organic. 15 that enables the coating of fiber (e.g., cotton yarn) with molten thermoplastic (e.g., PLA). an integrated system including a multi-input heater block, diameter control module and coiling system. It is a structure. In the method, natural / organic continuous fiber and biodegradable thermoplastic material are separated. The fibers are fed through channels into a multi-inlet heating block; the molten polymer passes through the fiber guide channel. It is directed into a chamber where the fiber-matrix undergoes controlled wetting / impregnation. Integration is ensured. The integrated composite melt exits the nozzle after calibration, and cooling takes 20 minutes. The area is dimensionally stabilized, and then the instantaneous diameter is measured using a laser diameter measurement module. Data is received and the pull-wind parameters are dynamically adjusted via feedback control; Thus, it can be wound onto reels with diameters of 1.75 mm, 2.85 mm, or non-standard diameters specific to the application. A continuous fiber-reinforced filament is obtained. The process involves natural fibers (e.g., cotton) and a biodegradable matrix. (e.g., PLA) by supporting combinations of environmental sustainability, low cost, wide range 25 It provides printer compatibility and repeatable diameter accuracy; it also offers intra-part orientation. without the need for reinforcement, in different sectors (manufacturing, education, agriculture, defense, architecture, etc.) supply of long-lasting and high-performance composite filaments suitable for direct printing It allows. Previous Tech 30 Today, filaments are used primarily in manufacturing, education, architecture, defense industry, aviation, and home. It caters to many sectors, including consumers and agriculture. Especially disposable products. The products are used in applications such as toys, packaging, and drip irrigation systems; at a low cost. 2 It enables environmentally friendly and health-conscious production. FFF / FDM Filaments used in 3D printing have historically been made from unreinforced thermoplastics (for example PLA, ABS, PETG) are composed of short fibers or particles used to improve mechanical performance. Filled filaments (carbon glass fiber chips, mineral filled, etc.) are also becoming common. However, short fiber reinforced solutions have a load of 5 due to discontinuous and non-directional distributions within the matrix. It improves the transfer only to a limited extent, fully addressing the weakness in Z-direction strength. This fails to resolve the issue and leads to new problems such as fragility and nozzle wear. Other At the end, a printer that delivers fiber directly into the part during printing using a "continuous fiber" approach. Although their capabilities have been improved, these architectures often require specialized hardware, complex path planning, and It requires a single-piece / single-machine-based process design; in-situ impregnation 10 and simultaneous orientation, precise control of fiber / filament pull-up speeds with melt rheology. This necessitates synchronization; even slight deviations from this will result in insufficient wetting. This leads to interface voids, diameter oscillation, and error-prone productivity. The current situation... In commercial pre-preg-like filament trials, however (polymer-pre-coated bundles) (filament formation) complete wetting of continuous fiber by viscous melt rheology / heat 15 It is tightly bound to the transfer window; in the case of natural / organic fibers, the fiber's The moisture content and thermal sensitivity of the cellulosic structure create an additional challenge. The fullness of the fiber Inability to wet it reduces shear strength at the fiber-matrix interface, leading to fatigue / crack propagation. fiber thermal degradation accelerates; conversely, when heating / stretching parameters are increased, fiber thermal degradation and The risk of discoloration arises. Also, commercially accepted printers use narrow 20mm or 1.75mm or 2.85mm printing surfaces. It expects tolerant filament diameters; in-line diameter measurement and closed-loop speed / tension control. In composite filaments produced without this, diameter oscillation and ovality occur even over short distances. This can lead to feeder gear skipping, nozzle clogging, and layer thickness issues. This leads to deviations. When the cooling and calibration stages are not properly configured, the internal components... Stresses accumulate, microcracks can form during winding onto the reel; reel density and 25 When line voltage is not monitored, the winding sequence experiences localized friction in the fiber bundle during "sharp" turns. It is displaced and local fiber accumulation or matrix depletion is observed in the filament. In summary... The current technique involves (i) a melt management that fully wets the continuous fiber and provides a homogeneous interface, (ii) Online measurement and closed loop ensuring diameter calibration within tight tolerances. (iii) tensile / winding control, (iii) a heat profile suitable for the thermal / moisture sensitivity of natural / organic fibers 30 and (iv) the final product is roll-shaped in a standard diameter and printer-compatible repeatable manner. Being able to hug is insufficient to meet all needs simultaneously. The current technique suffers from inadequate wetting, diameter / tolerance deviation, dependence on a specific head, and natural... Disadvantages of fibers, such as thermal / moisture-related problems, necessitate a new production method in this field. This makes it necessary to present it. 35 3 Patent document US12104044B2 describes a fiber-reinforced thermoplastic resin filament and This text discusses solutions related to molded / part output produced from this filament. The invention is a type of axially oriented reinforcing fiber, particularly suitable for use in 3D printers (FFF / FDM). Fiber-matrix interface thanks to surface treatment / sizing that includes and is compatible with thermoplastic matrix. It offers a filament architecture with increased strength. The invention is based on the type of fiber (e.g., glass / carbon / aramid 5). or natural fiber alternatives), fiber volume ratio and fiber cross-section, and matrix melt rheology (flow By establishing a balance between the index / pseudoplastic behavior, the diameter in the traction-cooling line It focuses on maintaining tolerance and intranozzle flow stability; it can crystallize as a matrix. and suitable amorphous thermoplastics (e.g., polyamide, polycarbonate, ABS, PETG, and the like). Complete wetting of the fibers within the melt temperature range, along with the shrinkage rate and cooling profile, is considered. 10 is obtained. It optimizes feed friction on the filament's outer surface and gear-idler interaction. While aiming for a surface quality that reduces slippage, the Z-direction interlayer of the printed part slip resistance, fiber alignment and printing parameters (nozzle temperature, printing speed, layer It is defined together with its thickness; heat annealing (anneal) or secondary treatment for molded / output parts. The processes exemplify dimensional stability and stress relief. Thus, the filament, both in the printer 15 It can be produced with tight diameter tolerances compatible with the supply chain, and also after printing. It provides a linear-d oriented strength increase to the part. Patent document EP3708707A1 describes a fiber-reinforced thermoplastic resin filament and technologies relating to molded / treated parts produced from the same material It is mentioned. The invention concerns the continuity of the fiber-matrix bond and the interface during printing. 20 resin composition that minimizes voids, fiber surface treatment, and It offers process temperature window combinations; fibers along the filament axis While load transfer in the horizontal plane is increased by alignment, the crystallization behavior of the matrix Cooling rate / crystal lamellar morphology and internal stress formation are controlled along with diameter stability. To reduce nozzle wear, the filler ratio and fiber length / cross-section are adjusted. It is limited by consideration of compatibility with the equipment; at the same time, the intermediate layer during printing. To prevent adhesion from deteriorating, the wettability of the filament surface and the adhesion temperature must be considered. The range is defined. This allows compatibility with printing parameters (e.g., 1.75 mm or 2.85 mm). (for their diameters) tight tolerance filaments are obtained; printed parts are subjected to mechanical tests. (Tensile / 3EN Bending / Impact) Significant increase in strength and rigidity compared to unreinforced reference equivalents. 30 and exhibits more predictable fracture behavior. Patent document number US2024 / 0294755A1 describes a fiber-reinforced thermoplastic resin filament. The text discusses the design and manufacturing principles related to parts produced from this filament. The invention relates to the homogeneous wetting of fiber bundles (rovings / yarns) with a molten matrix in filament production. Multi-channel / multi-zone heating, viscosity stepping, and traction-cooling to facilitate 35 It describes the coordination; thus, the formation of voids and interfacial separation along the fiber surface are minimized. 4 The filament diameter is reduced to a minimum by monitoring it with on-line measurement (e.g., laser optics) and pulling in a closed loop. speed adjustment, ovality / diameter oscillation during winding onto the reel, and fiber migration due to friction. It reduces the risks. On the matrix side, it protects interlayer adhesion during printing. The glass transition temperature and melt flow index window are given; on the fiber side, the surface energy compatibility is given. And damping (energy absorption) and toughness are balanced by fiber pull-out control after rupture. 5 As a result, the filament is stable in terms of printer feed and nozzle flow, and directional after printing. It is offered as a composite consumable material that provides increased strength / rigidity. Patent document EP4484474A1 describes a fiber-reinforced thermoplastic resin filament and The invention refers to molded / shaped products produced from it. The invention concerns the filament. axial cross-section and surface characteristics with printer feed mechanism and nozzle flow 10 It focuses on harmonizing fiber-matrix composition, wetting temperature, and shrinkage rate. By selecting them together, the continuity of the fibers in the axial direction is maintained. Internal cooling calibration. While stress concentration is reduced, diameter tolerance and surface smoothness are ensured throughout the entire process, including winding onto the reel. It is maintained throughout the logistics. The thermal shrinkage behavior of the matrix and the printing press By establishing a balance between bed / nozzle temperatures, the dimensional stability of the part is increased; fiber 15 the ratio of the hardware to increase the fracture toughness and fatigue resistance of the part. It is described by alignment combinations. This ensures the filament is compatible with standard printers. can be produced in mass production conditions and high-performance composite printed parts. available. Patent document US2020 / 0346399A1 describes 20 fiber-reinforced 3D printed materials. The approach is discussed. The invention relates to the printing process of continuous or semi-continuous fibers. principles of equipment and methods for controlled feeding, in / before the print head fiber wetting with resin, fiber tension and feed rate managed in a closed loop, layer It focuses on enhancing multiaxial load transfer through internal and interlayer fiber orientations. In-line monitoring and calibration that detects and compensates for fiber / filament breaks in the process flow. 25 The regions and correction strategies as needed are included; thus, fiber-matrix separation and Porosity problems caused by uneven wetting are minimized in printed composite parts. Targeted rigidity in tensile / bending / torsional loading thanks to the designed fiber paths. Strength profiles are obtained; printing parameters, nozzle temperature, bed temperature and deposition speed. By managing them together, dimensional stability and surface quality are maintained. 30 Patent document number US20140361460A1 describes a fiber-reinforced additive manufacturing process. The manufacturing approach is mentioned. The invention refers to a single or multiple units extending in the axial direction. a matrix containing multiple continuous / semi-continuous fiber cores and completely surrounding the core a "substantially void-free" composite filament made of material, printer feeding the filament into the nozzle and this filament being above the melting temperature of the matrix but fiber 35 It describes the extrusion of the core by heating it below its melting point. The invention applies to fibers. composite filament welding (spool or segment magazine), linear feeding systems, heated nozzle-guide channel and, if necessary, "plain" matrix material from a separate channel components such as a multi-material print head that enable its implementation work together. It presents an architecture. Thus, the formation of gaps at the fiber-matrix interface during printing and 5 Non-wetting areas are minimized, high load transfer along the fiber direction and interlayer Adhesion is achieved; the design maintains the continuity of the fiber core within the filament, This allows the part to gain rigidity / strength in the intended directions. Patent document EP3219474A1 describes a combination of multiple materials using a "spread tow tape". Fiber-reinforced composite 10 by combining matrix filaments using 3D printing / tape-laying method. The production of layers is discussed. The invention relates to the splicing station of the fiber strip. feeding, delivering multiple matrix filaments to the same station, these two under pressure by bringing them together, heating the matrix to its melting temperature, and creating an "impregnated fiber solid" (impregnated It includes the steps of creating the ply and laying this layer in sheets on the bed. At the splicing station, the heat-pressure-speed triad is controlled in a controlled manner, resulting in fiber wetting at 15 The goal is to ensure continuity and reduce void levels; through a layered placement strategy. The design of the composite component for multiaxial loading is supported. Thus, the printing During this process, fiber direction and matrix flow are synchronized, minimizing interface gaps, fiber breakage, and Typical defects such as diameter oscillation are reduced; the method uses both 3D printing and tape laying (tape It is explained that it can be adapted to (laying) scenarios. 20 Patent document number US20140061974A1 describes the creation of a continuous composite pathway using the "most" method. a small amount of material in liquid state, and at least one material completely submerged in liquid continuously. a method based on extruding the wires / rods together as "continuous strands" and The invention refers to a system in which two or more materials are extracted simultaneously. print head, liquid phase (e.g. thermoset / UV-curing resin or molten thermoplastic) 25 continuous fiber completely wrapping and proper curing / solidification after extrusion It involves hardening the composite path through a mechanism. Thus, the fiber is fully hardened during printing. The aim is to wet the surface and prevent the formation of interfacial gaps; the composite pathway is applied sequentially. It creates a three-dimensional component with laid-out tracks. The approach involves fiber tension and feed rate. coordinated management of the liquid material's rheology, curing rate, and nozzle outlet pressure. It defines a process window in which temperature / radiation conditions are kept within solidification limits. Patent document number US9156205B2 describes "the manufacture of composite filaments and the three types of these filaments." Solutions related to "use in 3D printers" are discussed. The invention is at the center. an axial fiber core (single strand or multi-strand bundle) and a polymer that completely surrounds the core. Obtaining a "gap-free" composite filament consisting of a matrix, the filament in question is 35 6 stable feeding from the reel to the printer input and the target matrix within the nozzle Heating-extraction-cooling to maintain fiber wetting within the melting / viscosity range. It describes the coordination of the stages. During printing, only composite filament or It is stated that production can be done with composite + plain matrix combinations; thus, the part Interlayer shear strength is increased depending on the fiber orientation strategy. The invention applies to feed 5. by considering the linear tolerances of the mechanism and the diameter stability along with the nozzle geometry, It aims for repeatable production at standard filament diameters (e.g., 1.75 mm) that printers expect. Patent document number US20200047402A1 describes continuous fibers (basalt, glass, carbon, etc.) the relationship between storage / feeding / wetting conditions and matrix deposition temperature 10 systems and methods for printing composite components, taking into consideration It is stated that the invention involves at least partial impregnation of a continuous fiber by a melt matrix. the adjustment of fiber advancement speed and fiber tension in a closed loop, between layers The fiber paths (in-plane and interlayer) must extend in specified directions and be printed. This includes regional differentiation of parameters (nozzle / plate temperature, deposition rate). By selecting a fiber material with a melting temperature above the process deposition temperature, the fiber 15 The integrity of the part is preserved; thus, multi-axial operation is achieved in the targeted regions of the part. Load transfer and dimensional stability are achieved. Patent document number WO2022175723A1 describes a continuous fiber reinforced thermoplastic filament. from an impregnation device in which fiber bundles are soaked with thermoplastic resin to obtain It is stated that the invention involves a system where continuous fibers (yarn / roving) are fed from an inlet, with a width of 20 The flow starts with a rectangular cross-section and narrows to a circular cross-section towards the exit. a device containing an impregnation cavity designed to oscillate sinusoidally throughout. It reveals. The invention demonstrates the opening / spreading in the fiber bundle with the sinusoidal shape of the flow path and It aims to increase the penetration of the resin into the fiber surface; cross-sectional transformation (from rectangle to circle) It ensures that the filament geometry is adapted to the printer feed at the output. Impregnation 25 Void formation is controlled by coordinating temperature and resin viscosity with fiber advancement rate. It is limited; diameter stability is maintained by calibration at the nozzle outlet. The device is used for wetting / molding, closed-loop control of the balance between the viscosity window and tensile stress enabling continuous printing compatible with “full wetting” and low ovality along the line. It enables the production of fiber-reinforced thermoplastic filaments. 30 Patent document EP3463818A4 describes continuous composite film / filament for "generative manufacturing". The concept is discussed. The invention is a composite with continuous length fiber reinforcement. film / filament in additive manufacturing processes such as 3D printing or tape-laying It tends to be used in; the material is laid in layers in additive production while the fibers are individually separated. Alignment in the direction and maintaining longitudinal continuity is essential. Classifications, 35 7 This indicates that the reinforcement consists of continuous fibers and refers to additive production head / nozzle solutions; The discussion focuses on mechanisms for wetting outside of the molding process and through continuous flow. In the process window, the wetting / exit geometry is determined by (e.g., from rectangular film to circular filament). (transformable molds) dimensional stability is ensured; internal stresses are reduced by cooling, tension- The diameter tolerance and surface smoothness are maintained through winding parameters. This approach, Additive 5 In manufacturing, interlayers reinforced in a single direction with continuous fibers are obtained with a low void ratio. It aims to improve the directional strength / rigidity of the printed parts. Patent document number US9156205B2 describes a "composite filament three-dimensional printer". Its architecture is discussed. The invention involves a fiber in the form of a continuous or multi-strand bundle at the center. 10 consisting of a core and a thermoplastic matrix layer that completely surrounds this core. "Substantially void-free" composite filament transferred stably from reel to printer. feeding and the fiber-matrix interface within the melting temperature range of the matrix inside the nozzle This ensures protection. The extrusion head geometry, heating profile, and traction ratio work together. By selecting the matrix, the continuity of the fiber is maintained without disrupting the matrix flow; if necessary, a plain matrix is used. Interlayer adhesion is supported by feeding additional material through the channel. On the printing side, 15 The aim is to achieve high load transfer along the fiber direction and an increase in interlayer shear strength; filament diameter tolerances, feed gear / nozzle flow, and standard printer requirements. It is determined in a way that will be compatible. Thus, the composite filament fed printer structure and this The production / application principles of the filament are systematically defined in a single document. Patent document number US20140361460A1 describes 20 methods for the manufacture of fiber-reinforced additives. It is stated that the invention involves a reinforced filament designed in a core-shell structure. (continuous or semi-continuous fiber in the core, thermoplastic matrix in the sheath) feeding into the nozzle, above the melting temperature of the matrix, below the melting softening range of the fiber core. extrusion within a controlled temperature window and interface gap during printing It describes the prevention of formation. The process involves the fiber advancement rate and tensile stress in the viscous matrix 25 synchronization with the flow, wetting the nozzle and calibration zones without leaving any gaps. It relies on shaping the surface in a way that will provide; surface energy matching for fiber-matrix surface. Process / sizing options, printing parameters (nozzle temperature, deposition rate, sheet thickness) and The cooling profile is considered together. Thus, the fiber direction in the printed part. While increasing strength / rigidity, interlayer adhesion in the Z-direction is achieved with the matrix flow window at 30°. It is protected. Patent document US20140061974A1 states that "at least one material must be in the liquid phase, and at least one and the material is extracted simultaneously as "continuous strand" The text discusses the production of composite paths. The invention is a multi-material print head. complete enveloping of the continuous fiber core by the liquid thermoplastic / thermoset matrix and 35 8 Cohesion is achieved through appropriate solidification (cooling or UV / chemical curing) at the exit. It defines the principle of ensuring fiber tension and feed rate are controlled via a closed loop, using fluid. The interface is achieved through the coordination of phase rheology with temperature / radiation limits at the nozzle outlet. The gap and wetting deficiency are minimized; thus, composite roads laid in series three It forms the 3D component. This mechanism prevents fiber-matrix separation, fiber breakage, and 5D damage during the printing process. It aims to reduce defects such as diameter oscillation and multiaxial load-bearing composite geometry. It enables its production. Studies have revealed that a significant problem with filaments used in FFF / FDM-based additive manufacturing is... This section consists of thermoplastics that are either unreinforced or filled with short fibers / particles. However, due to the discontinuous and often non-directional reinforcement distribution of the solutions, load transfer is limited. It increased the level of shear resistance but could not overcome the weakness in the Z-direction interlayer shear resistance, and also the nozzle. It appears to give rise to new problems such as wear and brittleness; on the other hand, "continuous fiber" In this approach, guiding the fiber to the part during printing requires specialized equipment and a complex pathway. The process window is narrowing because it requires planning, melt rheology – fiber advancement rate – tensile strength. Even small deviations in the voltage triplet result in insufficient wetting, interface gap (void), diameter 15 This leads to release and feed instability. The current pre-preg-like filament In their experiments, it was also found that due to the moisture and heat-sensitive nature of natural / organic fibers, the fiber's full... When a delicate balance cannot be struck between wetting and thermal degradation, interface slippage occurs. strength decreases, internal stresses and ovality increase, local fibers shift during winding onto the reel. Defects such as migration and matrix loss occur; also, on-line diameter measurement and closed 20 In lines without pull-through / winding control, printers are expected to have tight diameter tolerances (e.g. Since continuity cannot be ensured (1.75 mm / 2.85 mm), feeder gear leaks and nozzle malfunctions occur. Blockages and layer thickness deviations are observed. Ultimately, the problems mentioned above, which cannot be solved with the current technology, are related to the technical aspects. This has made it necessary to make an innovation in the field. 25 Purposes and Brief Description of the Invention The main objective of the invention is to achieve complete and continuous integration of organic fibers within a molten thermoplastic matrix. Standard diameter, compatible with printers, and rewound to ensure gapless wetting. The goal is to obtain a composite 3D printing filament. This allows for the creation of a 30-fiber interface. Directional strength / rigidity is increased by ensuring repeatable bond formation, and short fiber / particle filled. Interlayer weaknesses observed in comparable products are eliminated. Another aim of the invention is online diameter measurement and closed-loop pull-winding during production. The goal is to ensure that the filament diameter is kept within tight tolerances through control. This allows for a diameter of 1.75 9 Common printer requirements such as mm or 2.85 mm are reliably met, feed gear. Leaks and nozzle clogging are minimized. Another objective of the invention is to integrate natural / organic fibers (e.g.) with multi-inlet heating blocks and guide channels. (cotton yarn) impregnated under conditions suitable for rheology and heat profile without undergoing thermal degradation. This ensures fiber integrity, reduces interfacial void formation, and fiber-5 The shear strength of the matrix increases. Another aim of the invention is to improve the ovality of the filament through a calibrated nozzle + controlled cooling stages. The goal is to achieve dimensional stability without internal stress accumulation. This allows the pulley to... Defects such as local fiber migration and matrix loss during winding are prevented, and during storage-transportation- Diameter stability is maintained throughout the supply chain. 10 Another purpose of the invention is to provide special wetting / guidance equipment during printing. The advantage of continuous fiber is that it can be used within the part without requiring any additional materials. This allows the user... It can print directly with the existing FFF / FDM printer infrastructure and target the part. High load transfer is achieved in these directions. Another aim of the invention is to create 15 sustainable material combinations (e.g., cotton + PLA). The goal is to reduce environmental impact and cost. This is achieved through the use of biodegradable matrix and natural fibers. Its use reduces the carbon footprint and increases the accessibility of raw materials. Another objective of the invention is to analyze the combination of heat zones, outlet geometry, and traction speed in the production line. The goal is to expand the gap-free impregnation window through coordination. This allows for the application of different fibers. Even with varying fineness and matrix viscosities, repeatable quality is ensured. 20 Another objective of the invention is to improve surface quality and friction properties through the feeding mechanism. The goal is to adjust it to be compatible. This reduces slippage at the gear-idler contact, ensuring a stable connection. The nozzle flow rate is maintained, and the interlayer adhesion parameters are kept within the desired range. Another purpose of the invention is to ensure quality from production to the field by measuring diameter, ovality, and winding tension. and online monitoring and recording of reel fill metrics. This allows 25 Batch-by-batch consistency is ensured, backward traceability is strengthened, and process deviations are quickly identified. It will be corrected. Another objective of the invention is the geometric transformation of the heater block cross-section and the flow path. The goal is to improve fiber bundle opening / dispersion and surface wettability through optimization. This improves matrix penetration along the fiber surface and reduces the risk of interfacial gaps. 30 Another objective of the invention is to control microcracking and strain of the filament through cooling profile and winding torque. The goal is to ensure that the material is loaded onto the reel without piling up. This allows for better storage during this process. Property loss is prevented and long-term dimensional stability is maintained. Another aim of the invention is to create standard and customized versions to accommodate different printer and component requirements. 5 diameter options (e.g., 1.75 mm, 2.85 mm, and application-specific sizes) on a single line. It can be produced in this way. Thanks to this, multiple market requirements are met with a single process architecture, and The product range is expanded. Another aim of the invention is to improve mechanical performance (tensile, bending, impact, fatigue) without reinforcement. Compared to its counterparts, it offers a significant improvement at the component level. This allows for fine... Long-span / walled designs become possible, structural safety factors improve, and 10 Its application area expands. Another objective of the invention is to increase total production with an integrated line configuration suitable for mass production. The goal is to reduce costs. This allows for pre-preg-based intermediate steps or during printing. Efficiency is increased by eliminating the need for complex continuous fiber routing. All the objectives mentioned above and those that will emerge from the detailed explanation below are 15. The present invention aims to achieve the production of continuous organic fiber reinforced 3D printing filament. It is a system, and its feature is; An integrated production system that ensures controlled and uninterrupted line feeding of fiber. main structure, 20 Based on the main structure of the aforementioned integrated production system, the fiber is transferred from the source to the reel. a continuous organic fiber feed, from which it is taken and even its input is regulated unit, By working synchronously with the aforementioned continuous organic fiber feeding unit, the fiber advancement a fiber voltage regulator that provides closed-loop management of the voltage, 25 At the outlet of the aforementioned continuous organic fiber feeding unit, the fiber is fed through a multi-inlet hot water supply. a fiber guide channel that enables the fiber to be transported to the region without axial misalignment, Melting the thermoplastic filament and creating a pressurized melt flow. a thermoplastic filament melting and feeding unit that provides, The aforementioned thermoplastic melting and feeding unit flow and the aforementioned fiber guide 30 Multi-zone temperature where fibers coming through the channel are gathered and wetted Multi-inlet heater block with profile, Gap-free wetting at the fiber-matrix interface at the outlet of the aforementioned multi-inlet heater block. An impregnation chamber offering an improved flow path, 11 The aforementioned impregnation chamber subsequently has a narrow tolerance at the outlet cross-section. a calibrating nozzle that enables shaping and initial diameter calibration, Step-by-step to ensure dimensional stability and internal stress management along the line. a cooling and calibration zone that removes heat, Detecting quality threshold violations by instantaneous measurement of filament diameter on the production line. 5 an online laser diameter measurement module that enables this, Pulling speed and winding according to the data from the aforementioned online laser diameter measurement module. a feedback traction-winding station where the torque is dynamically adjusted, Enables the coordination of process parameters and recording of pipeline data. a central control and feedback unit and 10 Ensuring the final product is stored and logistics are carried out in accordance with printer-compatible standards. reel and storage unit It includes. The invention also describes a method for producing continuous organic fiber reinforced 3D printing filament. It includes the following steps in the method: 15 Drying and feeding of thermoplastic filament to remove moisture, Monitoring the conditions of the continuous organic fiber reel, and taking necessary precautions. drying and preparing the fiber end for the line entry, Initiation of line components, setting of multi-zone temperatures and melt rheology creation of the window, 20 Passing the fiber through the voltage regulator and maintaining the line voltage in a closed loop adjustment, The fiber is fed through the guide channel to the multi-inlet heating block and the axis correction of the abscess, Creating thermoplastic melt flow and ensuring pressure / viscosity balance, 25 Ensuring the fiber is fully saturated in the solution and removed from the impregnation chamber. passing, The composite melt is calibrated to the target initial diameter by passing it through a calibration nozzle. being done, Stabilizing the line by adjusting the initial pull speed and winding torque after exit. 30 being done, The filament is subjected to a gradual temperature gradient in controlled cooling channels. and reducing internal stress, Instantaneous measurement of filament diameter and detection of out-of-tolerance deviations using an online laser meter. perception, 35 12 Dynamic adjustment of traction speed and winding torque via closed-loop control, and Maintaining diameter tolerance, Monitoring filament surface quality and ovality, and issuing alarms in case of out-of-bounds situations. production, Once standard diameter and surface continuity are ensured, the filament is wound onto the reel and 5 Managing the winding layer arrangement, Monitoring reel fill rate, winding tension and line voltage, and Automatic reel changeover when needed, In-batch quality records and process data (temperature, pressure, tension, diameter measurement) recording in the production recipe and 10 In case of line change or stoppage, nozzles, flow channels and guide lines cleaning and conditioning the line for the next production run It includes the steps involved in the process. The best way to utilize the advantages of the existing invention, together with its structure and additional elements. For it to be understood, it must be evaluated together with the figures explained below. 15 Brief Description of the Figures Figure 1: On-line mixing of continuous organic fiber with molten thermoplastic matrix, the subject of the invention. Impregnated composite 3D printer that can be wound onto standard diameter reels compatible with the printer. This is a schematic view of the integrated production system for obtaining the filament. Reference Numbers 20 1. Main Structure of the Integrated Production System 11. Continuous Organic Fiber Feeding Unit 111. Fiber Tension Regulator 112. Fiber Guide Channel 12. Thermoplastic Filament Melting and Feeding Unit 25 13. Multi-Inlet Heater Block 131. Impregnation Chamber 132. Caliber Nozzle 14. Cooling and Calibration Area 15. Online Laser Diameter Measurement Module 30 16. Feedback Traction-Winding Station 17. Central Control and Feedback Unit 18. Reel and Storage Unit Detailed Description of the Invention 13 This detailed explanation focuses solely on the innovation in the invention to provide a better understanding of the subject. This is explained with examples that will not create any limiting effects. Accordingly, the following: The description and illustrations show continuous organic fiber reinforced 3D printing filament and its production method. It is explained. The subject of the invention, a schematic representation of which is given in Figure 1, is a continuous fiber reinforced 5 It is aimed at the production of a biodegradable composite 3D printing filament, and this production It includes equipment that performs the function. The filaments used in the previous technique are unreinforced or... The presence of short fibers or particles in composite structures affects the strength of the final product. It has a limited effect on increasing efficiency. This production system and method, which is the subject of the invention, and this technique... The gap is closed at both the product and production method levels. The subject matter of the invention is 10 In this method, a flexible, continuous organic fiber (e.g., cotton yarn) is placed in a separate guide channel. The molten thermoplastic (e.g., PLA) is brought into contact with the heat exchanger inside a multi-inlet heating block; inlet The design of the channels and temperature zones takes into account the moisture and heat sensitivity of the fiber during melting. Rheology / fiber velocity ensures complete and void-free wetting. Composite melt. After being removed from the calibrated nozzle, it is dimensionally stabilized through controlled cooling; 15 The online diameter measurement module located on the line produces instantaneous diameter data and is closed. The loop feedback pull-wind subsystem dynamically controls the pull speed / winding torque. By adjusting, it continuously maintains the target diameter tolerance. Thus, the matrix-fiber interface remains well-wetted. Standard printer diameters that do not exhibit brittle behavior due to fiber / filler discontinuity. A composite 3D printing filament that can be wound onto a reel is obtained. The product is suitable for 20 FFF / FDM printers. It is manufactured to be compatible with common feed-nozzle chains, and the user can customize it at the time of printing. Continuous fiber-reinforced mechanical welding without the need for wetting / guiding equipment. It achieves the desired performance. On the methodological side, the multi-input block design, the in-melt residence time of the fiber, and It prevents thermal degradation of organic fibers by managing heat input within a narrow window; draw-winding. By adjusting the tension and cooling profile together, internal stress accumulation and ovality are prevented; closed 25 Cycle control, despite minor environmental / raw material-related variations in the process. It provides repeatable diameter accuracy. The resulting invention is (i) printer-compatible, reel-wound. (i) product filament and (ii) multi-inlet heater block + calibration / cooling + circuit diameter of this filament Production method using an integrated in-line system consisting of measurement + feedback pull-wind components. Insufficient wetting in the current technique, diameter / tolerance deviation, dependence on a specific head, and natural 30 It comprehensively addresses thermal / moisture-related problems in fibers. The operating principle of the production system described in the invention is as follows: The integrated production system main structure (1) process, continuous fiber from source to stable line and begins with axial feeding; for this purpose, the fiber is fed with continuous organic fiber. The line is taken through unit (11), the progress voltage and tension fluctuations are fiber voltage 35 14 It is stabilized by closed loop management by the regulator (111) and the fiber axis It is transported to the hot zone inlet via the fiber guide channel (112) without any misalignment; simultaneously melting thermoplastic filament and creating a pressurized melt flow. The thermoplastic filament melting and feeding unit (12) is used. The fiber is fed by melt flow. It is assembled in a multi-inlet heater block (13) to be wetted under a zone temperature profile and 5 Optimized flow for complete impregnation without leaving gaps at the fiber-matrix interface. It is advanced through the impregnation chamber (131) via the path; subsequently the outlet section, the line target It is shaped with a calibrated nozzle (132) to bring it to diameter tolerance. Following the nozzle outlet dimensional stability and internal stress relief of composite filament in the cross-section, stepwise heat This is provided by the cooling and calibration zone (14) structured with the principle of removal; this 10 During this process, the filament diameter is measured instantly and without contact using an online laser diameter measuring system. The measured diameter data is continuously monitored by module (15). Central control and feedback. is evaluated by unit (17); tolerance deviation, ovality or trend shift When detected, the mentioned central control and feedback unit (17) adjusts the pulling speed and winding. by dynamically adjusting its torque via the feedback traction-winding station (16) line 15 It rebalances the voltage and line speed, melting the aforementioned thermoplastic filament when necessary. and the supply unit (12) and the mentioned multi-inlet heater block (13) corrective to the temperature zones. By sending commands, it keeps the melt rheology within the target window and performs the aforementioned cooling and Revise the cooling profile on the calibration zone (14); thus, the diameter tolerance, intermediate Facial cavity risk and internal stress accumulation are kept under simultaneous control. Stable and printer 20 Once a compatible diameter is obtained, the filament, winding layer arrangement and spool fill level are monitored. The reel is wound onto the reel and storage unit (18) in accordance with the standards; process Line data such as temperature, pressure, tension, and diameter measurements generated along the route are sent to the aforementioned central location. Tracking and quality by batch-by-batch by recording by the control and feedback unit (17) is guaranteed 25
Claims
REQUESTS 1. It is a continuous organic fiber reinforced 3D printing filament production system, characterized by: An integrated production system that ensures controlled and uninterrupted line feeding of fiber. main structure (1), Based on the main structure of the mentioned integrated production system (1), the fiber is transported from the source to the spool 5 a continuous organic fiber feed, from which it is taken and even its input is regulated unit (11), By working synchronously with the mentioned continuous organic fiber feeding unit (11), the fiber a fiber voltage regulator that provides closed-loop management of the increment voltage (111), 10 At the outlet of the continuous organic fiber feeding unit (11) mentioned, the fiber is fed through a multi-inlet hot a fiber guide channel (112) that enables the transport of fibers to the region without axial misalignment, Melting the thermoplastic filament and creating a pressurized melt flow. a thermoplastic filament melting and feeding unit (12), The mentioned thermoplastic filament melting and feeding unit (12) flow with the mentioned 15 The fibers coming through the fiber guide channel (112) are brought together and wetted multi-inlet heater block with zone temperature profile (13), There is no gap at the fiber-matrix interface at the output of the mentioned multi-input heater block (13). An Impregnation Chamber (131) offering an improved flow path for wetting, The impregnation chamber mentioned (131) and subsequently the outlet section within a narrow tolerance of 20 a calibrating nozzle (132) that provides shaping and initial diameter calibration, Step-by-step to ensure dimensional stability and internal stress management along the line. a cooling and calibration zone that removes heat (14), Detecting quality threshold violations by instantaneous measurement of filament diameter on the production line. an online laser diameter measurement module (15) that enables 25 Pulling speed and winding according to the data of the mentioned online laser diameter measurement module (15) a feedback traction-winding station (16) in which the torque is dynamically adjusted, Enables the coordination of process parameters and recording of pipeline data. a central control and feedback unit (17) and A 30-day period where the final product is stored and logistics are ensured in accordance with printer-compatible standards. reel and storage unit (18) It includes.
2. The invention is a method for producing 3D printing filament reinforced with continuous organic fibers, characterized by: 16 Drying the thermoplastic filament and melting it to create thermoplastic filament melting and to be taken to the feeding unit (12), Inspection of the conditions of the continuous organic fiber reel, and taking precautions if necessary. drying and continuous organic fiber feeding unit (11) line of fiber end preparing for the entrance, 5 Initiation of line components, multi-zone temperatures multi-inlet heater block (13) and thermoplastic filament melting and feeding unit (12) is set up and the process Monitoring via central control and feedback unit (17), Passing the fiber through the fiber voltage regulator (111) and closing the line voltage setting as a cycle, 10 Hot through the fiber guide channel (112) without creating axial misalignment of the fiber being sent to the entrance of the region, Thermoplastic melt flow with thermoplastic filament melting and feeding unit (12) formation and maintenance of melt pressure / viscosity equilibrium within the process window, Multi-inlet heating block (13) 15 to ensure complete wetting of the fiber in the melt. combining inside and continuing the flow through the impregnation chamber (131), The composite melt is passed through the calibrated nozzle (132) and the outlet cross-section is brought to the target. initial diameter calibration, The initial pull speed and winding torque following the nozzle exit are feedback pull-winding. Adjustment and stabilization of the line on station (16), 20 Stepwise temperature gradient within the filament cooling and calibration region (14) by subjecting it to dimensional stability and internal stress relief, Instantaneous and contactless online laser diameter measurement module on the line (15) by measuring and detecting deviations outside of tolerance, Closed-loop control with central control and feedback unit (17) traction 25 dynamic speed and winding torque via feedback pull-winding station (16) adjustment and, if necessary, thermoplastic filament melting and feeding unit (12), on the multi-inlet heater block (13) and cooling and calibration area (14) application of corrective instructions, Filament surface quality and ovality data from the online laser diameter measurement module (15) 30 and monitoring with central control and feedback unit (17) alarms, When standard diameter and surface continuity are ensured, the filament is stored in the reel and storage unit. (18) winding onto and feedback pull-winding of the winding layer arrangement managed by station (16), 17 Central control and feedback of reel fill rate, winding tension and line voltage. monitoring by the feeding unit (17) and automatic reel change when necessary to be performed on the reel and storage unit (18), In-batch quality records and measurements such as temperature zones, pressure, traction speed, and diameter. process monitoring data to the central control and feedback unit (17) database 5 recording, Calibrated nozzle (132), multi-inlet heater block in case of line change or stop. (13) Cleaning of process channels including flow path and fiber guide channel (112) and conditioning the line for the next production run, It includes the steps of the process. 10