Composite Additive Manufacturing via Interlocking Segments
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Solution Overview
Problem
Conventional additive manufacturing techniques, such as stereolithography, face limitations in producing composite articles that combine polymeric and non-polymeric components with desired structural and mechanical properties, particularly in achieving secure interlocking features.
Innovation Solution
A method involving dual cure resins and continuous liquid interface production (CLIP) is used, where a first component is immersed in a polymerizable liquid, irradiated with light, and then advanced away from the build surface to form a second component, with optional washing and further solidification to create a composite article with interlocking segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional stereolithography techniques are used to form layers at the top or bottom surface, then three-dimensional objects can be constructed in a step-wise manner, but the production of composite articles with secure interlocking features and desired structural properties is limited
Solution Approach 1:
The method performs preliminary actions by first forming an intermediate object with a first three-dimensional interfacing segment, then immersing it in polymerizable liquid and forming a second component with a second three-dimensional interfacing segment that contacts the first segment. This preliminary formation of interfacing segments enables secure interlocking in the final composite article, resolving the limitation of conventional techniques that cannot produce reliable composite structures with interlocking features.
2Productivity
If dual cure stereolithography resins are used with CLIP techniques, then rapid production of three-dimensional objects with desirable structural and mechanical properties is enabled, but there remains a need for additional techniques to produce composite articles
Solution Approach 1:
The invention segments the composite article into distinct components: a first component with a first three-dimensional interfacing segment and a second component with a second three-dimensional interfacing segment. The first component is formed as an intermediate object, then the second component is formed on it by immersing in polymerizable liquid and irradiating. This segmentation enables the production of composite articles with secure interlocking features while maintaining the productivity benefits of CLIP techniques.
3Ease of manufacture
If new layers are formed at the top surface of the growing object, then additive manufacturing can be performed, but achieving secure interlocking features for composite articles is difficult
Solution Approach 1:
The method embeds the first three-dimensional interfacing segment within the second three-dimensional interfacing segment structure. The first component with its interfacing segment is immersed in polymerizable liquid, and the second component forms around it, creating a nested configuration where the first interfacing segment is enclosed or surrounded by the second interfacing segment. This nesting provides secure interlocking and enhances the strength of the composite article.
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 production of composite articles with enhanced structural and mechanical properties by ensuring secure interlocking features and adherence between components, overcoming the limitations of existing techniques.
Implementation Method 1
forming an intermediate object by irradiating the build region with light through the optically transparent member and also advancing the first three-dimensional component and the build surface away from one another to form from the polymerizable liquid a second component
Data Source
AI summary
A method of making a composite article comprised of a first component (10) and a second component (30) includes (a) providing a first component (10) and an optically transparent member (22) having a build surface with the first component having a first three-dimensional interfacing segment formed thereon; (b) immersing the first three-dimensional interfacing segment in polymerizable liquid (21); (c) forming an intermediate object by irradiating a build region with light through an optically transparent member and also advancing the first three-dimensional component and the build surface away from one another to form from the polymerizable liquid (21) a second component (30) on said first three-dimensional interfacing segment, with the second component including a second three-dimensional interfacing segment in contact with the first three-dimensional interfacing segment; then (d) optionally washing the intermediate; and then (e) further solidifying the second three-dimensional component (30) on said first three-dimensional component (10) to form said composite article.