3D-Printed High-Temperature Composite Structures With Near-Net Shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for fabricating high-temperature composite structures, such as carbon-carbon (C/C) and ceramic matrix composite (CMC) structures, are labor-intensive, costly, and time-consuming, often requiring intricate textile weaving, autoclave curing, and extensive machining, which can introduce defects and are not suitable for forming large, complex structures with void spaces.
Innovation Solution
A method involving 3D printing of precursor structures using fiber-reinforced matrix materials, followed by pyrolysis and impregnation with a liquid resin, allowing for the formation of high-temperature composite structures with oriented fibers, low porosity, and complex void spaces like sandwich structures, using robotic 3D printing machines that can operate in multiple axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fabrication techniques (textile weaving, autoclave curing) are used, then composite structures can be formed, but the process becomes labor-intensive, costly, and time-consuming
Solution Approach 1:
The patent changes the fabrication process parameters by using additive manufacturing instead of conventional textile weaving and autoclave curing. This transforms the production method from labor-intensive manual processes to automated robotic deposition, significantly reducing fabrication time while maintaining structural integrity through controlled material placement and layered building
Solution Approach 2:
The patent replaces the mechanical textile weaving system with an additive manufacturing system that deposits precursor material layer by layer. This substitution eliminates the need for complex weaving machinery and manual labor, reducing both time and cost while achieving the same structural formation through a different physical process
2Manufacturing precision
If conventional fabrication methods are used, then composite blocks can be formed, but extensive machining is required which introduces defects and adds to time and cost
Solution Approach 1:
The patent performs preliminary shaping during the additive manufacturing process itself, building the structure in near-net-shape configuration. This preliminary action eliminates or minimizes the need for subsequent extensive machining operations, thereby preventing the introduction of machining defects while maintaining dimensional accuracy
Solution Approach 2:
The patent extracts the shaping operation from the post-fabrication stage and integrates it into the fabrication process. By forming the final geometry directly during additive manufacturing, the patent removes the harmful machining step entirely, eliminating defect generation while preserving manufacturing precision
3Ease of manufacture
If conventional techniques are used, then solid blocks can be fabricated, but the process requires expensive tooling and molds
Solution Approach 1:
The patent employs a robotic additive manufacturing system that can fabricate diverse composite structures without requiring dedicated molds or tooling for each part. This universal system performs multiple functions (deposition, shaping, layering) through software control, eliminating the need for expensive, part-specific tooling while reducing overall fabrication cost
Solution Approach 2:
The patent uses digital models as copies or representations of the final part geometry to guide the additive manufacturing process. Instead of physical molds, the digital copy contains all shape information, which is translated into physical form layer by layer, eliminating the need for expensive physical tooling while maintaining manufacturing ease
4Reliability
If conventional methods are used, then composite structures can be formed, but assembling multiple parts is required which increases time and risk of gaps
Solution Approach 1:
The patent merges multiple separate fabrication operations into a single additive manufacturing process, building the entire structure as one integrated component. This merging eliminates the need for assembling multiple parts, preventing gap formation at joints while reducing total fabrication time despite the complexity of the single-piece structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of near-net-shape high-temperature composite structures with improved structural integrity, reduced porosity, and the ability to form large, complex parts with minimal machining, overcoming the limitations of conventional techniques.
Implementation Method 1
forming a 3D precursor structure comprises depositing, along a direction, an amount of a filament material. The filament material comprises a precursor matrix material having embedded therein a fiber material.
Implementation Method 2
The 3D precursor structure is pyrolyzed to form a pyrolyzed intermediate structure.
Implementation Method 3
The pyrolyzed intermediate structure is impregnated with a liquid resin to form an impregnated structure.
Implementation Method 4
The impregnated structure is exposed to a high-temperature environment to solidify material from the liquid resin within pores of the pyrolyzed intermediate structure.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000°F (1093°C)) include forming precursor structures by additive manufacturing ("AM") (e.g., "3D printing). The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.