Composite Printing via Controlled Fibre Bundle Orientation
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Solution Overview
Problem
Current additive manufacturing techniques fail to effectively orient and vary the orientation of short fibre bundles within a composite material, limiting their mechanical and thermal performance, especially in articles like brake discs where different stress areas require tailored fibre distribution.
Innovation Solution
A method and apparatus that aligns fibre bundles before deposition, allowing for controlled orientation and length within a polymer matrix using mechanical or electromagnetic alignment, and simultaneous use of multiple nozzles for precise fibre placement and resin addition, enabling the creation of articles with enhanced mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional additive manufacturing techniques are used with continuous fibres, then the process complexity is reduced, but the ability to create varied fibre orientations and lengths within the same article is limited
Solution Approach 1:
The continuous fibre supply is segmented into discrete fibre bundles of controlled length (3-50mm) that can be independently oriented and placed. This segmentation allows different fibre orientations in different regions of the article while maintaining process control through automated handling of individual bundles.
Solution Approach 2:
The invention adds the dimension of fibre bundle orientation control in three-dimensional space (X, Y, Z axes) to the traditional layer-by-layer deposition process. This enables fibres to be oriented at different angles and directions within the same layer, creating complex reinforcement patterns that match stress distributions in the final article.
2Strength
If fibre bundles are deposited without alignment, then the deposition process is simpler, but the mechanical and thermal properties of the composite material are reduced
Solution Approach 1:
Fibre bundles are pre-aligned along their longitudinal axis before deposition using alignment means that apply mechanical or electromagnetic forces. This preliminary alignment ensures that fibres are properly oriented before being incorporated into the matrix, maximizing their reinforcement effect while keeping the alignment mechanism separate from the deposition process.
Solution Approach 2:
The invention employs electromagnetic fields instead of purely mechanical alignment systems to orient fibre bundles. This substitution enables more precise and flexible control of fibre orientation, including the ability to adjust orientation dynamically during deposition, while reducing mechanical complexity in the alignment system.
3Manufacturing precision
If multiple nozzles are used for simultaneous fibre and resin deposition, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
Multiple deposition functions (fibre bundle delivery, resin injection, and deposition control) are merged into an integrated multi-nozzle system that operates in coordination. This merging allows precise simultaneous deposition of fibres and resin in the correct proportions and positions, while sharing common control and positioning infrastructure to mitigate complexity increases.
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
Enables the production of composite materials with improved mechanical and thermal strength by allowing fibre bundles to be oriented and positioned according to specific stress directions, enhancing the technical and economic value of products like brake discs for automotive and aerospace applications.
Implementation Method 1
aligning bundles (2) along a predetermined path X, X′... through a laying means (62)... incorporating at least part of bundles (2) in a matrix (6, 8)... wherein the reinforcement fibres (4) are in the range of about 1,000-100,000 for each bundle (2)
Implementation Method 2
A method and apparatus that aligns fibre bundles before deposition, allowing for controlled orientation and length within a polymer matrix using mechanical or electromagnetic alignment
Implementation Method 3
laying and solidifying at least one layer of matrix (6, 8) with bundles (2) to make the composite material (1)
Implementation Method 4
laying and solidifying at least one layer of matrix (6, 8) with bundles (2) to make the composite material (1)
Data Source
AI summary
The present invention relates to a method of printing a composite material (1), for example polymeric, carbonaceous, siliconic or metallic comprising steps of:i) providing a plurality of bundles (2) of reinforcement fibers (4), wherein the reinforcement fibers (4) have a length in the range 3-50 mm and are in the number of about 1,000-100,000 in each bundle (2);ii) aligning the bundles (2) along a predetermined path (X, X′);iii) incorporating at least part of the bundles (2) into a matrix (6, 8), for example polymeric, carbonaceous, siliconic or metallic, preserving the alignment along said path (X, X′);iv) laying and solidifying at least one layer (8) of the matrix (6, 8) of step iii) to make the composite material (1).