Additive Manufacturing Functional Elements Existing Components

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Solution Overview

Problem

Existing additive manufacturing technologies face challenges in embedding functional elements like wires and optical fibers into existing structures, limiting the enhancement of structural strength and functionality.

Innovation Solution

A method involving the discharge of a liquid matrix and reinforcement materials, such as wires or optical fibers, into features of existing components, followed by curing, using a nozzle system with a robotic head and cure enhancers to create a composite structure that can enhance the strength and functionality of the existing components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional additive manufacturing is used to create three-dimensional parts by depositing overlapping layers of material, then new structures can be fabricated with desired shapes and properties, but functional elements like wires and optical fibers cannot be embedded into existing structures

Engineering Contradiction:

Improveability to embed functional elementsVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by first discharging the liquid matrix material into the existing structure, creating a prepared bed that receives and secures the functional elements. This preliminary matrix discharge establishes the foundation before the functional elements are embedded, enabling subsequent integration without requiring complex simultaneous multi-material deposition

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The liquid matrix serves as an intermediary material that facilitates the embedding of functional elements into existing structures. The matrix material acts as a bonding medium that secures wires, optical fibers, and other functional elements within the structure, enabling integration without direct mechanical fastening or complex joining processes

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If continuous fibers are embedded within material discharging from the print head during fabrication, then structural strength is multiplied beyond matrix-dependent strength, but application to existing structures becomes problematic

Engineering Contradiction:

Improvestructural strengthVSAvoidapplicability to existing structures

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of embedding fibers during the matrix discharge process (traditional CF3D approach), the patent inverts the sequence by first discharging the matrix material and then embedding the functional elements into the matrix bed. This reversal enables integration with existing structures while maintaining the strength benefits of fiber reinforcement

Inventive Principle:

Principle #13The other way round (Inversion)

3Adaptability or versatility

If multiple tracks of material are discharged sequentially to embed functional elements, then functionality is enhanced, but manufacturing time and process complexity increase

Engineering Contradiction:

Improvefunctional element integrationVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent applies segmentation by dividing the manufacturing process into distinct sequential stages: first discharging the matrix material to create a bed, then embedding functional elements, and finally discharging additional matrix material to complete the structure. This segmentation allows each operation to be optimized independently while maintaining overall efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent maintains continuity of useful action by ensuring that each discharge operation flows seamlessly into the next without idle time. The nozzle system continuously deposits matrix material or embeds functional elements without interruption, and the robotic head moves continuously along the tool path, minimizing non-productive time between operations

Inventive Principle:

Principle #20Continuity of useful action

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

Enables the embedding of functional elements into existing structures, increasing their strength and functionality while allowing for the creation of complex shapes and structures with improved mechanical properties.

Implementation Method 1

curing the liquid matrix

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS10857729B2System and method for additively manufacturing functional elements into existing components

Publication Date: 2020.12.08 CONTINUOUS COMPOSITES INC

AI summary

A method is disclosed for additively manufacturing a composite structure. The method may include discharging from a nozzle into a feature of an existing component a first track of material including at least a liquid matrix. The method may also include discharging from the nozzle into the first track of material a second track of material including at least one of a wire and an optical fiber, and curing the liquid matrix.