Additive Manufacturing Composite Parts with Variable Fiber Orientation
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Solution Overview
Problem
Conventional composite manufacturing methods, such as sequential layering of plies with unidirectional or randomly oriented fibers, result in increased weight due to inefficient reinforcement fiber orientation and limitations in implementing advanced structural designs.
Innovation Solution
A system for additively manufacturing composite parts using a delivery guide to deposit a continuous flexible line comprising a non-resin component and a partially cured photopolymer-resin component, with controlled curing energy delivery to orient fibers in desired orientations and enhance structural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sequential layering of multiple plies with unidirectional or randomly oriented fibers is used, then composite parts can be manufactured, but the weight of the finished part increases because not all reinforcement fibers are oriented along the direction(s) of the force(s) to be applied
Solution Approach 1:
The patent applies local quality by varying the fiber orientation angle θ along the length of the continuous fiber reinforcement according to a specific mathematical function. This allows each local region of the composite part to have fibers optimally oriented for the local stress state, maximizing structural efficiency and minimizing weight compared to uniform fiber orientation schemes
Solution Approach 2:
The patent employs dynamics by continuously changing the fiber orientation angle θ as a function of position along the reinforcement. This dynamic adjustment of fiber orientation enables the composite structure to adapt to varying stress distributions throughout the part, achieving optimal strength-to-weight ratio that static, uniform fiber layouts cannot accomplish
2Ease of manufacture
If sequential layering of multiple plies is used, then composite parts can be manufactured, but limitations inherent to laminar techniques prevent implementation of many types of advanced structural designs
Solution Approach 1:
The patent applies segmentation by dividing the continuous fiber reinforcement into multiple discrete reinforcements, each with its own optimized fiber orientation function. This allows complex three-dimensional structures to be built by assembling multiple optimized segments, achieving both manufacturability through systematic layering and design versatility through flexible segmentation of the overall structure
Solution Approach 2:
The patent employs composite materials by combining continuous fiber reinforcement with matrix material in a tailored configuration. The continuous fibers provide structural strength while the matrix binds them together, creating a composite structure that achieves advanced designs unattainable with single materials or traditional laminar techniques
3Strength
If continuous fiber reinforcement with varying fiber orientation angle is used, then optimal fiber orientation can be achieved, but the complexity of the manufacturing system increases
Solution Approach 1:
The patent replaces complex mechanical fiber orientation control systems with a computational approach. Fiber orientation angles are determined through mathematical functions and computer algorithms rather than complex mechanical adjustment mechanisms, reducing device complexity while maintaining the ability to achieve optimal fiber orientations for structural efficiency
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 allows for the creation of lightweight composite parts with tailored properties by ensuring optimal fiber orientation and improved structural integrity, enabling the implementation of complex designs that traditional methods cannot achieve.
Implementation Method 1
The source of the curing energy is configured to deliver the curing energy at least to a portion of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide
Data Source
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AI summary
A system (100) for additively manufacturing a composite part (102) comprises a delivery guide (112) and a surface (114), at least one of which is movable relative to another. The delivery guide (112) is configured to deposit at least a segment (120) of a continuous flexible line (106) along a print path (122). The print path (122) is stationary relative to the surface (114). The continuous flexible line (106) comprises a non-resin component (108) and a photopolymer-resin component (110) that is partially cured. The system 100 further comprises a feed mechanism (104) configured to push the continuous flexible line (106) through the delivery guide (112). The system 100 further comprises a source (116) of a curing energy (118). The source (116) is configured to deliver the curing energy (118) at least to a portion (124) of the segment (120) of the continuous flexible line (106) after the segment (120) of the continuous flexible line (106) exits the delivery guide (112).