Composite Filament for Additive Manufacturing via Polymer Permeation
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Solution Overview
Problem
Current additive manufacturing technologies are limited by the materials' narrow temperature range and low strength characteristics, making it difficult to produce high-strength composite structures.
Innovation Solution
A composite filament is developed by immersing a continuous high-strength filament in a solution with a dissolved polymer, allowing the polymer to permeate the filament, and then removing the solvent to create a composite material suitable for additive manufacturing, which can be co-extruded with a formation material to form strong and complex structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional extrusion materials are used in additive manufacturing, then the process is simple and materials are easy to handle, but the strength characteristics are low and temperature range is narrow
Solution Approach 1:
The patent applies composite materials by combining continuous high-strength filaments (such as carbon fiber, glass fiber, or aramid) with a polymeric matrix material. The continuous filaments are embedded within the extruded polymeric material, creating a composite structure that provides both high strength characteristics and ease of handling. This composite approach allows the additive manufacturing process to produce parts with enhanced mechanical properties while maintaining the simplicity of filament-based extrusion.
2Strength
If high-strength composite materials are attempted, then strength improves, but the material becomes difficult to extrude and process
Solution Approach 1:
The patent applies local quality by distributing continuous high-strength filaments throughout the polymeric matrix in a controlled manner. Rather than attempting to extrude already-formed composite materials, the process embeds reinforcement filaments locally within the extrudable polymeric material during the extrusion process itself. This allows the matrix material to remain easy to extrude while the embedded filaments provide localized strength enhancement where needed.
3Reliability
If conventional materials are used, then processing is easy and equipment requirements are simple, but the structures cannot withstand high thermal, chemical, and mechanical stresses
Solution Approach 1:
The patent applies preliminary action by pre-embedding continuous high-strength filaments into the polymeric matrix before the extrusion and deposition process. The filaments are prepared and positioned in advance within the extrudable material, so that when the composite filament is extruded and deposited layer by layer, the reinforcement structure is already in place. This preliminary preparation enables the final structure to withstand high thermal, chemical, and mechanical stresses without requiring complex post-processing or specialized equipment.
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
The composite filament enables the production of stronger, more flexible structures capable of withstanding high thermal, chemical, and mechanical stresses, suitable for high-performance applications, and allows for the reinforcement of parts in non-orthogonal directions, overcoming the limitations of conventional materials.
Implementation Method 1
During the immersion, the dissolved polymer can permeate the continuous filament
Implementation Method 2
the dissolved polymer can permeate the continuous filament
Implementation Method 3
the solvent can be removed from the wet composite filament by air drying, heating, or any other suitable process
Data Source
AI summary
A composite filament for use in additive manufacturing such as fused filament fabrication is described along with methods of its construction and use. The composite filament includes a single continuous filament (e.g., a continuous carbon roving) and a polymer (e.g., a high glass transition polymer) in intimate contact. The composite filament is formed through immersion of the continuous filament in a solution of the polymer. The composite filament can be combined with an additional formation material in an additive manufacturing process.