Additively Manufactured Ceramic Composite Components
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Solution Overview
Problem
Conventional methods for forming ceramic matrix composite (CMC) components are time-consuming and prone to defects due to the complexity of preparing pre-impregnated plies and multiple processing steps.
Innovation Solution
The use of a tow deposition device to extrude and cure impregnated ceramic fibers with a curable resin layer-by-layer on a substrate, controlled by a computing device, to form additively manufactured composite components, reducing processing steps and defects while enabling the creation of complex CMC components with higher accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to form CMC components through pre-impregnated plies and multiple processing steps, then manufacturing capability is maintained, but processing time increases and defects occur
Solution Approach 1:
The patent combines multiple separate processing steps (fiber placement, resin impregnation, curing) into a single integrated additive manufacturing process. The tow deposition device simultaneously deposits ceramic fiber tows and applies curable resin coating, eliminating the need for separate pre-impregnated ply preparation and multiple processing cycles, thereby reducing processing time and defect rates
Solution Approach 2:
The patent replaces conventional mechanical handling of pre-impregnated plies with an automated tow deposition device that uses controlled extrusion and deposition mechanisms. The computing device controls the deposition process parameters, replacing manual or semi-manual handling operations with automated systems that reduce human error and improve consistency
2Ease of manufacture
If conventional methods with multiple processing steps are used, then manufacturing capability is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent segments the composite material into discrete impregnated tows that can be deposited individually and controlled independently. Each tow is pre-impregnated with resin as a discrete unit, allowing precise control over material deposition and simplifying the overall manufacturing process compared to handling large pre-impregnated plies
Solution Approach 2:
The patent changes the physical state and form of the materials from solid pre-impregnated plies to extrudable impregnated tows with controlled resin content. The curable resin coating on each tow allows for controlled curing parameters, transforming the manufacturing process from complex multi-step mechanical handling to controlled material deposition and curing
3Manufacturing precision
If additive manufacturing with tow deposition is used, then processing time is reduced and accuracy is improved, but new manufacturing technology complexity is introduced
Solution Approach 1:
The patent implements self-service through the automated control system where the computing device monitors and adjusts deposition parameters based on pre-programmed models. The tow deposition device automatically controls fiber placement and resin application without requiring manual intervention, and the system includes built-in controls for maintaining consistent tow diameter, resin coating uniformity, and layer alignment
Solution Approach 2:
The patent incorporates feedback mechanisms where the computing device receives data from sensors monitoring the deposition process and adjusts parameters in real-time. The system tracks tow deposition rate, resin coating thickness, and layer formation quality, making corrective adjustments to maintain manufacturing precision and compensate for variations in material properties
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 significantly reduces processing time and defects, allows for the creation of complex CMC components with fewer steps, and results in higher accuracy compared to traditional methods.
Implementation Method 1
Each respective impregnated tow includes at least one ceramic fiber and a curable resin coating the at least one ceramic fiber. The technique includes curing the curable resin to form a cured composite component.
Data Source
AI summary
An example technique includes extruding, by a tow deposition device, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a layer of material on a major surface of a substrate. Each respective impregnated tow includes at least one ceramic fiber and a curable resin coating the at least one ceramic fiber. The example technique includes curing the curable resin to form a cured composite component. An example system includes a tow deposition device, an energy source, and a computing device. The computing device is configured to control the tow deposition device to extrude, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a layer of material, and is configured to control the energy source to cure the curable resin to form a cured composite component.