Composite 3D Printing Path Control for Continuous Fiber Placement
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Solution Overview
Problem
Current additive manufacturing technologies face challenges in efficiently controlling the deposition of composite materials with continuous fibers, particularly in creating complex structures with high strength and precision, as they often require manual intervention and lack automated systems for optimizing fiber placement and matrix curing.
Innovation Solution
A method and system for additive manufacturing that involves slicing a virtual model into layers, applying infill patterns, distributing points along these patterns, and using a processor to validate and filter paths for an additive manufacturing machine to deposit a matrix-coated continuous reinforcement, ensuring precise placement and curing of composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated control systems are implemented for composite material deposition, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The control system is segmented into distinct functional modules: a slicing module that divides the 3D model into layers, a path generation module that creates deposition trajectories, and a control module that executes deposition. This modular segmentation manages complexity while maintaining high precision fiber placement through specialized algorithms in each module.
Solution Approach 2:
The system performs preliminary actions by pre-processing the 3D model into 2D slices and pre-calculating optimal deposition paths before actual manufacturing. This preliminary computation of trajectories and parameters enables precise fiber placement during execution without real-time complexity, as the path planning is completed in advance.
2Strength
If continuous fibers are embedded within discharged material, then structure strength is improved, but control difficulty increases
Solution Approach 1:
The system replaces manual mechanical control with automated computer-controlled mechanisms. The control system automatically calculates and executes precise fiber placement trajectories, substituting human operator control with algorithmic path planning and automated deposition control, thereby maintaining ease of operation while achieving superior structural strength through consistent fiber embedding.
3Manufacturing precision
If complex infill patterns are applied to optimize structure properties, then manufacturing precision is improved, but processing time increases
Solution Approach 1:
Complex infill patterns and optimal structure properties are pre-calculated during the path generation phase before actual deposition. The system performs preliminary optimization of infill patterns based on structural requirements, allowing precise property optimization during manufacturing without real-time processing delays, as the complex computations are completed in advance.
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 enables the automated fabrication of composite structures with enhanced strength and complexity, allowing for the creation of structures with desired cross-sectional shapes and properties, improving manufacturing efficiency and precision.
Implementation Method 1
A method and system for additive manufacturing that involves slicing a virtual model into layers, applying infill patterns, distributing points along these patterns, and using a processor to validate and filter paths
Implementation Method 2
causing the additive manufacturing machine to discharge material along the validated at least one path
Implementation Method 3
Upon exiting the print head, a cure enhancer (e.g., a UV light, a laser, an ultrasonic emitter, a heat source, a catalyst supply, etc.) is activated to initiate and/or complete curing (e.g., hardening, cross-linking, sintering, etc.) of the matrix
Data Source
AI summary
A method is disclosed for additively manufacturing a structure. The method may include slicing a virtual model of the structure into a plurality of layers, applying at least one infill pattern to each of the plurality of layers, and distributing a plurality of points along lines of the at least one infill pattern. The method may also include sequentially grouping the plurality of points into at least one path, validating the at least one path for fabrication by an additive manufacturing machine, and causing the additive manufacturing machine to discharge material along the validated at least one path.