Continuous Fiber Composite Print Head with Integrated Matrix Coating
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Solution Overview
Problem
Existing continuous fiber 3D printing systems face limitations in enhancing the strength and structural integrity of composite structures, particularly in the operation and configuration of the manufacturing systems, which can be improved for more efficient reinforcement and matrix application.
Innovation Solution
The system includes a print head configured to discharge continuous reinforcements partially coated with a liquid matrix, featuring a low-pressure port and a pump to manage the matrix flow, along with a support for moving the print head and a controller to adjust pressure and movement during fabrication, enabling precise control over reinforcement alignment and matrix application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fibers are embedded within a matrix to increase structure strength, then the mechanical strength of the composite structure is improved, but the complexity of the manufacturing system increases due to the need for precise fiber placement and matrix application control
Solution Approach 1:
The patent combines the fiber delivery system and matrix application system into a single integrated print head assembly. The matrix is applied directly to the continuous fibers as they exit the print head, merging two separate processes (fiber placement and matrix coating) into one unified operation, thereby reducing overall system complexity while maintaining composite structure strength
Solution Approach 2:
The print head is designed as a multi-functional device that simultaneously performs fiber dispensing, matrix coating, and initial curing operations. This universal device handles multiple functions that would traditionally require separate equipment, reducing the overall complexity of the manufacturing system while enabling continuous fiber reinforcement
2Device complexity
If a moveable print head discharges matrix and fibers in free space to fabricate unsupported structures, then the manufacturing flexibility and complexity are reduced, but the precision of matrix application and fiber alignment deteriorates
Solution Approach 1:
The system incorporates sensors that monitor the position and orientation of the print head, as well as the flow rates of fibers and matrix in real-time. This feedback is fed to the controller to dynamically adjust discharge parameters, ensuring precise matrix application and fiber alignment even during free-space fabrication with moveable print heads
Solution Approach 2:
The print head system is designed with dynamic control capabilities, allowing real-time adjustment of matrix flow rate, fiber feed rate, and print head positioning during fabrication. This dynamic adaptability enables the system to maintain manufacturing precision while operating in flexible free-space configurations
3Adaptability or versatility
If the matrix is cured immediately upon exiting the print head to allow unsupported structures, then the fabrication flexibility is improved, but the time for complete curing and structural stabilization is reduced
Solution Approach 1:
The system applies a preliminary curing action immediately at the print head using UV light or heat to create an initial set that allows the structure to support itself in free space. This preliminary curing enables fabrication flexibility while the complete curing process continues afterward to achieve full structural stabilization
Solution Approach 2:
The curing process is divided into periodic stages: initial rapid curing at the print head for immediate structural support, followed by continued curing during fabrication, and final complete curing after fabrication. This periodic approach balances fabrication flexibility with adequate curing time at each stage
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 configuration enhances the structural strength of composite structures by ensuring optimal reinforcement alignment and matrix distribution, allowing for the creation of complex shapes with increased unsupported length and improved mechanical properties.
Implementation Method 1
a low-pressure port located upstream of the outlet and configured to draw out only liquid matrix
Data Source
AI summary
A system is disclosed for additively manufacturing an object. The system may include a support, and a print head having an outlet and being connected to and moveable by the support in a normal travel direction during discharge of material from the print head. The system may also include a first device operatively connected to the print head at a trailing location relative to the normal travel direction. The first device may be configured to expose the material to a cure energy. The system may further have a second device operatively connected to the print head at a location trailing the first device relative to the travel direction. The second trailing device configured to expose the material to a cure energy.