Layered Composite Manufacturing With Barbed Metal Laminae
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Solution Overview
Problem
Current methods for manufacturing three-dimensional composite structures with metal and non-metal laminae are inefficient and lack automation, resulting in high material and fabrication costs, and do not effectively utilize the strength of metal and substrate materials.
Innovation Solution
A method and system for additive manufacturing involving cutting barbed metal sheets and substrate sheets into planar pieces, positioning them in an alternating pattern, and pressing the metal pieces' barbs into the substrate to bind them together, optionally using fasteners for additional security, allowing for automated and cost-effective production of high-strength multi-layer composite structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for composite structures, then material and fabrication costs are high, but automation and manufacturing efficiency are low
Solution Approach 1:
The manufacturing process segments the composite structure into individual laminae that are cut, textured, and assembled separately. Each lamina is prepared independently with barbs formed on its surface, then assembled in an automated stacking process to form the final composite structure, enabling both high productivity and automation.
Solution Approach 2:
Barbs are formed on the laminae surfaces in advance during the cutting/preparation stage, before assembly. This preliminary action of texturing the surfaces with barbs enables automated assembly processes to quickly bind laminae together without requiring complex real-time bonding operations, thereby increasing both automation and manufacturing efficiency.
2Strength
If more material is used to ensure structural strength, then strength is improved, but weight and material usage increase
Solution Approach 1:
The invention uses composite structures formed by alternating layers of metal and substrate materials bonded together through barb penetration. This composite approach allows the structure to achieve high strength by utilizing the complementary properties of different materials (metal strength and substrate bulk) while minimizing the total amount of material needed compared to solid metal construction.
Solution Approach 2:
Barbs are formed only on the surfaces of laminae that require bonding, rather than throughout the entire structure. This localized feature provides maximum bonding capability at the interfaces where strength is needed, while keeping the bulk material lightweight and minimizing overall weight.
3Shape
If complex shapes are manufactured using traditional methods, then shape complexity is achieved, but manufacturing cost and time increase
Solution Approach 1:
Complex three-dimensional shapes are segmented into a series of two-dimensional cross-sectional laminae. Each lamina is cut to the required shape using automated cutting equipment, then stacked and assembled to form the complete three-dimensional structure. This segmentation allows complex shapes to be manufactured efficiently through automated processes rather than expensive traditional machining.
Solution Approach 2:
The invention transitions from manufacturing complex three-dimensional shapes directly to stacking two-dimensional laminae that define cross-sections of the desired shape. By working in two dimensions for each lamina and stacking them in sequence, the system achieves complex three-dimensional geometries through a simpler, more cost-effective automated process.
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 approach enables the efficient and cost-effective production of high-strength multi-layer composite structures with reduced material usage and weight, suitable for various applications, including load-bearing and complex shapes, while maintaining the strength of metal and the bulk of substrate materials.
Implementation Method 1
pressing the metal pieces and substrate pieces together to force the barbs of the metal pieces to penetrate the substrate pieces and bind the metal pieces and substrate pieces together
Data Source
AI summary
A system for additive manufacturing of a three-dimensional object, comprising: a controller for identifying a set of planar cross-sectional shapes of the three-dimensional object, the set extending in a sequence from a first end of the three-dimensional object to a second end of the three-dimensional object; a three-dimensional scanner, associated with the controller, configured to scan a prototype of the three-dimensional object to generate a computer-aided design model; at least one cutting station for cutting at least one barbed metal sheet into a plurality of individual planar barbed metal pieces corresponding to the cross-sectional shapes; and for cutting at least one substrate sheet into a plurality of individual planar substrate pieces corresponding to the cross-sectional shapes, wherein the at least one substrate is penetrable by the barbs; and a binding station for receiving and pressing the individual barbed metal pieces and the individual substrate pieces together.