Additive Manufacturing Head Integrating Compaction and Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing continuous fiber 3D printing systems face limitations in enhancing the strength and structure of composite materials, particularly in the operation and configuration of manufacturing systems, which can be improved for increased fiber reinforcement and reduced void content.
Innovation Solution
An additive manufacturing system with a print head that discharges continuous reinforcement coated in a matrix, utilizing a compactor to compact the reinforcement and matrix, and a cure enhancer to direct cure energy through the compactor, ensuring precise curing and alignment of fibers for enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber reinforcement is used to increase structure strength, then the strength of the composite structure is multiplied beyond matrix-dependent strength, but the system complexity and difficulty of achieving proper fiber alignment and curing increases
Solution Approach 1:
The patent combines the compaction function and curing function into a single integrated head assembly. The compactor rollers work in conjunction with UV LEDs positioned within the same housing, allowing simultaneous densification and curing of the composite material as it is deposited. This integration reduces system complexity compared to having separate compaction and curing systems while maintaining the strength benefits of continuous fiber reinforcement.
Solution Approach 2:
The head assembly serves multiple functions: it deposits the composite material, compacts the fibers and matrix, and cures the matrix through integrated UV LEDs. This multi-functional design eliminates the need for separate compaction rollers and curing devices, resolving the technical contradiction by reducing system complexity while maintaining enhanced structure strength through proper fiber alignment and curing.
2Manufacturing precision
If compaction is applied to increase fiber volume and reduce void content, then the structural integrity is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent integrates compaction rollers directly into the printing head assembly, combining the deposition and compaction functions in one unit. This eliminates the need for separate post-deposition compaction equipment, reducing manufacturing process complexity while achieving the desired fiber volume and void reduction for improved structural integrity.
Solution Approach 2:
The compaction action is performed continuously during the deposition process rather than as a separate post-processing step. The rollers continuously densify the composite material as it is being laid down, maintaining continuity of the manufacturing action and simplifying the overall process while achieving consistent structural integrity throughout the printed part.
3Adaptability or versatility
If immediate curing is performed to enable unsupported structures in free space, then unsupported structures can be fabricated, but control over cure depth and uniformity becomes difficult
Solution Approach 1:
The patent positions UV LEDs at specific locations within the head assembly, including within the compactor housing, to provide localized curing zones. This allows different regions of the deposited material to receive appropriate cure energy based on their specific needs, enabling precise control over cure depth and uniformity while maintaining the ability to fabricate unsupported structures in free space.
Solution Approach 2:
The compactor housing serves as an intermediary structure that houses and positions the UV LEDs in optimal locations. This intermediary element allows the curing function to be integrated into the compaction process while providing the geometric control needed for precise cure depth management, resolving the contradiction between versatility and manufacturing precision.
4Strength
If fiber alignment is improved to enhance composite strength, then the interlaminar strength increases, but the complexity of achieving proper fiber orientation during deposition increases
Solution Approach 1:
The patent combines fiber deposition and fiber alignment functions by using the compactor rollers to both lay down the composite material and simultaneously align the fibers through the mechanical action of passing through the material. This integration eliminates the need for separate fiber alignment mechanisms while achieving improved interlaminar strength through proper fiber orientation.
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 system achieves higher interlaminar strength, increased fiber volume, and reduced void content by compacting and precisely curing the matrix and reinforcement, allowing for the creation of stronger, more complex composite structures with improved structural integrity.
Implementation Method 1
a compactor configured to compact the continuous reinforcement and the matrix
Implementation Method 2
a cure enhancer configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor
Data Source
AI summary
A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to discharge a continuous reinforcement that is at least partially coated in a matrix, and a compactor configured to compact the continuous reinforcement and the matrix. The system may also include a cure enhancer configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor.