3D Printed Composite Layer for High Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing processes for producing shape components are limited in achieving high mechanical strength, as the strength of the components can only be influenced by the choice of starting material, and materials with high strength in the hardened state are rare due to thermal requirements.
Innovation Solution
The process involves generating an additional layer using a spray method with fiber pieces, which improves the mechanical properties of the shape component by better absorbing forces. This layer can be oriented to enhance strength and can include a binding agent to further stabilize the fiber pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard 3D printing processes use thermoplastic materials such as ABS, PLA, acrylates, epoxies, or polyurethanes, then the manufacturing process is simple and production time is short, but the mechanical strength of the molded component is limited
Solution Approach 1:
The patent combines thermoplastic starting materials with thermosetting resin-impregnated fiber fragments (carbon, glass, aramid) to create a composite structure. The thermoplastic matrix provides ease of manufacturing through standard 3D printing processes, while the thermosetting resin-infused fibers contribute high mechanical strength and stiffness. This composite approach allows the component to benefit from both material systems without requiring complete replacement of the printing material.
Solution Approach 2:
The patent applies fiber-reinforced layers selectively at specific locations within the molded component rather than uniformly throughout. The fiber fragments are embedded in certain layers to provide localized strength enhancement where mechanical loads are expected, while other layers maintain the simplicity of standard thermoplastic printing. This allows optimization of strength where needed without compromising manufacturing ease elsewhere.
2Strength
If fiber-reinforced layers are added to improve mechanical strength, then the strength of the molded component increases, but the production time and process complexity increase
Solution Approach 1:
The fiber fragments are pre-impregnated with thermosetting resin before being incorporated into the 3D printing process. This preliminary impregnation allows the fibers to be ready for immediate integration into the printed structure without requiring additional resin application steps during printing. The pre-prepared fiber-reinforced layers can be directly deposited by the 3D printer, maintaining production efficiency while achieving enhanced mechanical properties.
3Strength
If fiber fragments are used to improve mechanical properties, then the strength increases, but the weight of the component increases
Solution Approach 1:
The patent implements fiber reinforcement selectively in specific layers and regions where mechanical strength is most needed, rather than uniformly throughout the entire component. This localized approach ensures that weight is added only where it provides functional benefit for load-bearing, while other regions maintain lower weight characteristics. The fiber fragments are concentrated in areas experiencing highest stress or requiring enhanced structural integrity.
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 production of shape components with high strength and mechanical resilience, enabling the creation of components with filigree structures that maintain strength under mechanical load, while also reducing manufacturing time and costs.
Implementation Method 1
The process involves generating an additional layer using a spray method with fiber pieces
Implementation Method 2
This layer can be oriented to enhance strength and can include a binding agent to further stabilize the fiber pieces
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for producing a shaped component (1), wherein the shaped component (1) is produced from a plurality of layers (5) arranged one over the other, and wherein at least one layer (5) is produced from a starting material (9) in the printing method at least in some regions and a further layer is produced in the spraying method by use of fiber pieces (6) at least in some regions.