Composite Filament 3D Printing with Ironing Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D printing technologies face challenges in efficiently generating toolpaths for composite filament fabrication, particularly in creating complementary toolpaths that avoid stress concentrations and seam accumulation between layers, which affects the structural integrity and consistency of printed parts.
Innovation Solution
A method involving the use of multi-strand core reinforced filaments with substantially continuous reinforcing strands, where composite swaths are deposited with an ironing force to spread the strands, allowing for the creation of consolidated composite swaths with reinforcing strands oriented parallel to the filament length, and toolpaths are controlled to overlap and interact in specific patterns to distribute stress and reinforce layers effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional toolpaths are used for composite filament fabrication, then the printing process is simple, but stress concentrations and seam accumulation occur between layers affecting structural integrity
Solution Approach 1:
The toolpath is divided into multiple segments including primary reinforcement paths, secondary reinforcement paths, and transition regions. Each segment serves a specific function in distributing stress and avoiding seam accumulation, thereby improving structural integrity without requiring overly complex integrated toolpaths
Solution Approach 2:
The patent introduces a third dimension to toolpath planning by considering inter-layer reinforcement patterns. Secondary reinforcement paths are placed in adjacent layers at different orientations to complement the primary reinforcement, creating a three-dimensional reinforcement structure that distributes stress more effectively
2Manufacturing precision
If reinforcing strands are spread against deposition surface with ironing force, then fiber distribution is improved, but the process complexity increases
Solution Approach 1:
The ironing process utilizes the material's own properties - the heat and pressure from the deposition head itself spread the reinforcing strands and consolidate the matrix material. This self-consolidating mechanism improves fiber distribution without requiring additional external consolidation equipment
Solution Approach 2:
The patent controls the ironing force parameters (pressure, temperature, dwell time) to optimize fiber distribution. By adjusting these parameters during deposition, the process achieves precise control over strand spreading and consolidation while maintaining a relatively simple single-pass deposition operation
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 enhances the structural integrity and consistency of printed parts by reducing stress concentrations and seam accumulation, improving the distribution of reinforcing fibers across layers, leading to stronger and more reliable 3D printed structures.
Implementation Method 1
applying an ironing force that spreads the reinforcing strands within the filament against a deposition surface
Implementation Method 2
flowing the matrix material and applying an ironing force that spreads the reinforcing strands
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
In a method for additive manufacturing, a multi- strand core reinforced filament including a flowable matrix material and substantially continuous reinforcing strands extending in a direction parallel to a length of the filament is supplied. A first consolidated composite swath of a height less than ½ the width of the filament is deposited in a first reinforcement formation including at least one straight path and at least one curved path against a deposition surface, and a second consolidated composite swath of a height less than ½ the width of the filament is deposited in a second reinforcement formation against the first consolidated composite swath. Each deposition flows the matrix material and applies an ironing force to spread the reinforcing strands within the filament against the underlying surface and/or previously deposited swath.