Additive Manufacturing Print Head for Composite Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing continuous fiber 3D printing systems lack control over compacting and curing of reinforcement, which affects the placement, strength, and accuracy of composite structures.
Innovation Solution
An additive manufacturing system with a print head that discharges a matrix-wetted continuous reinforcement, compresses it using a module, and directs cure energy radially outward through an outer cover to enhance curing and compacting, allowing for improved reinforcement placement and structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber reinforcement is embedded within matrix material during additive manufacturing, then the strength of the structure is multiplied beyond matrix-dependent strength, but control over compacting and curing of the reinforcement is insufficient, affecting placement, strength, and accuracy
Solution Approach 1:
The print head is segmented into distinct functional modules: a discharge outlet for matrix-wetted reinforcement, a roller compaction module with adjustable pressure, and a cure energy source. This segmentation allows independent optimization of each function - discharge control, compaction control, and curing control - thereby achieving both high strength and precise reinforcement placement
Solution Approach 2:
The system performs preliminary actions by pre-wetting the reinforcement with matrix material before discharge, and applying compaction pressure immediately upon discharge while the material is still pliable. The cure energy is then applied promptly to lock in the desired configuration. These preliminary actions ensure proper consolidation and positioning before final curing, improving both strength and placement accuracy
2Ease of operation
If a head-mounted cure enhancer is activated immediately upon exiting the print head to initiate and complete curing of the matrix, then unsupported structures can be fabricated in free space, but control over the curing process and its effect on reinforcement consolidation is limited
Solution Approach 1:
The system employs dynamic control of the curing process by adjusting the timing, intensity, and duration of cure energy application based on real-time process conditions. The cure enhancer can be activated at different stages - during discharge, during compaction, or after consolidation - allowing optimization of both free space fabrication capability and curing control precision for different application requirements
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 provides greater control over reinforcement placement and curing, resulting in enhanced structural strength and accuracy of composite structures manufactured using the system.
Implementation Method 1
pressing a module against the matrix-wetted continuous reinforcement after discharging to compress the matrix-wetted continuous reinforcement
Implementation Method 2
a head-mounted cure enhancer (e.g., a UV light, an ultrasonic emitter, a heat source, a catalyst supply, etc.) is activated to initiate and/or complete curing of the matrix
Data Source
AI summary
An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head configured to discharge a material and being operatively connected to and moveable by the support in a normal travel direction during material discharge. The print head may include a module located at a trailing side of the discharging material relative to the normal travel direction and being configured to compact the material and expose the material to a cure energy at a tool center point.