Composite Additive Manufacturing Layer Registration
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Solution Overview
Problem
Additive manufacturing techniques face challenges with registration inaccuracies, leading to lower part quality due to mis-registration of layers, which can result in errors of up to 100 to 250 microns, primarily caused by electro-mechanical complexities in image forming systems.
Innovation Solution
A composite-based additive manufacturing process that involves staging fibrous materials like carbon fiber sheets, using a gantry system with a movable print head and powder deposition device, applying a liquid to the fibers, dusting with plastic powder, removing excess powder, and applying pressure and heat to sinter and compress each layer precisely, ensuring accurate registration of part layers relative to support layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional image forming systems with electro-mechanical components are used for layer deposition, then the system can achieve complex shape fabrication, but registration inaccuracies of 100 to 250 microns occur due to electro-mechanical complexities
Solution Approach 1:
The patent replaces traditional electro-mechanical image forming systems with a direct digital deposition approach. Instead of using complex electro-mechanical components that cause mis-registration, the system uses computer-controlled direct material placement methods that eliminate the intermediate electro-mechanical conversion steps, thereby achieving both complex shape fabrication and high registration accuracy
Solution Approach 2:
The patent uses digital models and computer-aided design (CAD) to create precise virtual copies of the desired object geometry. These digital models are then directly translated into physical layers through computer-controlled deposition, eliminating the need for traditional electro-mechanical image forming systems and achieving sub-100-micron registration accuracy
2Adaptability or versatility
If support structures are added to enable complex shape fabrication, then structural support is provided, but mis-registration between part components and support components occurs
Solution Approach 1:
The patent replaces mechanical support structures with digital support generation algorithms. The support structures are computationally designed and deposited with the same precision as the part itself, using the same direct deposition system. This eliminates the mis-registration problem between part and support components that occurs with separate support structure fabrication and assembly
Solution Approach 2:
The patent merges the fabrication of support structures with the fabrication of the part itself into a single integrated process. Both the part and support structures are deposited simultaneously or in sequence using the same computer-controlled deposition system, ensuring that they are registered with each other with the same high precision, eliminating mis-registration issues
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 method enhances precision in additive manufacturing, achieving significantly improved piece part accuracy by ensuring perfect registration of part layers to support layers, thereby improving the quality of 3D objects built.
Implementation Method 1
applying a liquid to the fibers, dusting with plastic powder
Implementation Method 2
applying pressure and heat to sinter and compress each layer precisely
Data Source
AI summary
A system and method are provided enabling higher precision in composite based additive manufacturing (‘AM”). The method includes staging a fibrous material such as carbon fiber sheets by potentially cutting to length and placing a sheet onto an elevator. Above the elevator is a gantry that holds a moveable print head and a powder deposition device as well as an excess powder recapture device. A liquid is placed onto the fiber by the print head such that when the subsequent step of dusting the area with a plastic powder, the powder sticks to the area where the liquid was imaged. Subsequently, excess powder is removed and pressure and potentially heat are applied to sinter the layer and compress to the desired height.