3D Printed Carbon Fiber Composites via Layered Substrate Infiltration
Solution Overview
Problem
Current three-dimensional printing methods are limited by a restricted materials palette and slow build speeds, which hinder the creation of complex objects with desirable properties such as high strength and low weight.
Innovation Solution
The method involves forming a 3D object using layered composite materials, where thermoplastic or thermoset powders are selectively deposited onto carbon fiber substrate layers, melted, and hardened to fuse the layers together, allowing for the creation of strong, lightweight composite materials with varied properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional 3D printing methods are used, then objects can be fabricated, but the build speed is slow and material selection is limited
Solution Approach 1:
The patent uses composite materials consisting of substrate layers (such as paper, fabric, or thin plastic sheets) combined with powdered material (thermoplastic or thermoset). This composite approach enables both rapid fabrication through layer-by-layer assembly and expanded material versatility by combining different substrate types with various powders to achieve desired material properties including high strength and low weight characteristics
Solution Approach 2:
The fabrication process segments the object into thin layers, with each layer composed of substrate material and selectively deposited powder. This segmentation allows for rapid sequential assembly of layers while maintaining control over material composition and properties in different regions of the object
2Ease of manufacture
If substrate layers are used without flattening, then the process is simpler, but planar imperfections such as waviness and crimping affect quality
Solution Approach 1:
The substrate layers are pre-flattened through heating and pressing operations before powder deposition. This preliminary action removes waviness, crimping, and wrinkles from the substrate, ensuring a smooth planar surface for accurate powder adhesion and high-quality object fabrication, while the heating process also prepares the substrate for subsequent bonding
3Manufacturing precision
If thermoplastic powder is selectively deposited only in some regions, then material is saved and precision is improved, but the process complexity increases
Solution Approach 1:
The patent uses liquid binding agents as an intermediary to facilitate selective powder deposition. The liquid is applied to specific regions of the substrate layer first, creating adhesive zones that selectively attract and hold powder particles. This intermediary approach enables precise selective deposition without requiring complex deposition mechanisms, as the liquid binding agent naturally guides powder placement through capillary action and 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 approach enables the rapid fabrication of large, complex 3D objects with enhanced material properties, surpassing traditional methods in speed and material versatility, and allows for the use of conventional thermal inkjet heads, reducing costs and improving efficiency.
Implementation Method 1
thermoplastic or thermoset powders are selectively deposited onto carbon fiber substrate layers, melted, and hardened to fuse the layers together
Implementation Method 2
melted, and hardened to fuse the layers together
Implementation Method 3
Heat is applied (or heat and pressure are applied) to the powder and substrate, causing the powder, not the substrate, to melt
Data Source
AI summary
A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion. Flattening a substrate layer involves reducing planar inconsistencies or imperfections, and comprises applying heat to each substrate layer, cooling the substrate layers, and optionally applying tension and/or pressure to the heated and cooled substrate layers.