3D Printer for Void-Free Fiber-Reinforced Composite Filaments
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Solution Overview
Problem
Current three-dimensional printing techniques lack the ability to efficiently produce composite parts with the benefits of composite lay-up and filament winding, particularly in creating durable and UV-stable structures with concave shapes, due to issues with air voids and fiber alignment.
Innovation Solution
A three-dimensional printing method using unmelted void-free fiber-reinforced composite filaments, where the filament is heated and ironed to melt the matrix material, applying tension to the fibers to prevent buckling and ensure bonding, allowing for the creation of durable and UV-stable parts with complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional FFF extrudes successive filament beads of ABS or similar polymer, then the printing process is simple and fast, but the parts lack durability and UV stability
Solution Approach 1:
The patent uses fiber-reinforced composite filaments where continuous fibers (such as carbon, glass, or aramid) are embedded within a polymer matrix. This composite structure provides both the productivity of automated printing and the reliability of composite materials, achieving durable, UV-stable parts with enhanced mechanical properties while maintaining manufacturing efficiency.
Solution Approach 2:
The patent employs controlled heating to melt the polymer matrix material while maintaining fiber reinforcement. By precisely controlling the thermal parameters during extrusion, the process achieves proper bonding between layers while preserving fiber integrity, thus obtaining durable parts with improved UV stability without sacrificing printing speed.
2Reliability
If composite lay-up uses preimpregnated composite sheets with resin binder, then durable and UV-stable parts are produced, but the process is complex and time-consuming
Solution Approach 1:
The patent replaces the manual mechanical lay-up process with an automated extrusion system. The continuous fiber-reinforced filament is fed through a heated nozzle that melts the matrix material and deposits it layer by layer, automatically forming complex three-dimensional structures without requiring manual sheet handling, alignment, or pressing operations.
Solution Approach 2:
The patent uses successive layers of extruded composite material deposited in a controlled sequence. Each layer is deposited, cooled, and bonded to the previous layer in a repetitive cyclic process, building up the part incrementally. This periodic deposition action simplifies the manufacturing process while maintaining the durability and UV stability of composite materials.
3Ease of manufacture
If composite filament winding winds tows around a mandrel, then rotationally symmetric parts are produced, but concave shapes cannot be formed due to taut filaments bridging
Solution Approach 1:
The patent uses a flexible extruded filament instead of taut wound tows. The melted matrix material allows the fiber reinforcement to conform dynamically to complex geometries including concave surfaces. The extrusion process can deposit material precisely where needed, allowing the filament to follow complex toolpaths and form three-dimensional concave shapes that would be impossible with traditional filament winding.
Solution Approach 2:
The patent changes the physical state of the matrix material from solid (in traditional winding) to molten during deposition. This parameter change allows the material to flow and conform to complex geometries, enabling the formation of concave shapes and irregular surfaces while maintaining fiber alignment and structural integrity through controlled cooling and solidification.
4Strength
If fiber reinforced composite filament is heated to melt matrix material, then bonding between layers is improved, but air voids may form reducing part quality
Solution Approach 1:
The patent employs controlled heating with temperature monitoring to melt the matrix material uniformly. The extrusion system regulates the thermal parameters and deposition rate to ensure complete fusion between layers without trapping air voids. This feedback-controlled process maintains optimal temperature to achieve strong interlayer bonding while preventing void formation that would compromise part quality.
Solution Approach 2:
The patent uses continuous extrusion of the fiber-reinforced filament with constant heating and deposition. The uninterrupted flow of molten matrix material ensures continuous bonding between layers as the filament is deposited, preventing air entrapment. This continuous action maintains consistent temperature and pressure to achieve void-free, high-quality parts with strong interlayer adhesion.
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
This method enables the production of strong, durable, and UV-stable composite parts with reduced air voids and improved fiber alignment, allowing for the construction of parts with concave shapes and enhanced structural integrity.
Implementation Method 1
The filament is heated to a temperature greater than a melting temperature of the matrix material to melt the matrix material interstitially within the filament
Implementation Method 2
The filament is heated to a temperature greater than a melting temperature of the matrix material to melt the matrix material interstitially within the filament
Implementation Method 3
A ironing force is applied to the melted matrix material and the one or more axial fiber strands of the fiber reinforced composite filament with an ironing lip
Implementation Method 4
The unmelted composite filament is fed at a feed rate along a clearance fit zone that prevents buckling of the filament
Data Source
AI summary
Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to applying the filament from the conduit nozzle.