Composite Sheet Additive Manufacturing for Structural Load-Bearing
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Solution Overview
Problem
Conventional three-dimensional printing (3DP) methods are not well-suited for producing large, structural components with significant load-bearing or wear-resistant capabilities due to limitations in the distribution and continuity of structural materials like carbon fiber and fiberglass within each layer.
Innovation Solution
The method involves positioning sheets of composite material, curing predetermined portions, cutting the sheets to create processed layers, and repeating this process to build up a component, using a machine with subsystems for positioning, curing, and cutting, and optionally applying adhesives and pressure to ensure bonding and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional 3DP methods are used to deposit small amounts of material at a time, then intricate three-dimensional structures can be constructed, but the structural material does not run in continuous form throughout each layer, limiting load-bearing capacity
Solution Approach 1:
The patent segments the structural material into discrete sheets that are sequentially deposited and cured. Each sheet contains continuous structural material (fibers, fabrics, or particulate matter embedded in resin) that provides load-bearing capacity, while the layer-by-layer segmentation enables construction of intricate three-dimensional structures.
2Strength
If thermoset resins with high-strength particles are used in 3DP, then load-bearing capability is improved, but the structural material is provided in very small amounts at a time and does not run in continuous form
Solution Approach 1:
The patent implements continuity of useful action by using sheets where structural material (fibers, fabrics, or particulate matter) runs in continuous, uninterrupted form throughout each layer. The sheets are cured immediately upon deposition to maintain this continuous structural reinforcement, ensuring load-bearing capability is achieved without the discontinuity inherent in conventional small-deposition methods.
3Strength
If sheets of composite material are used with continuous structural material, then load-bearing capacity is improved, but the process requires curing and cutting steps
Solution Approach 1:
The patent merges multiple functions into integrated subsystems. The curing subsystem uses UV lights or other energy sources to immediately cure the resin matrix upon sheet deposition. The cutting subsystem uses lasers, water jets, or mechanical cutters to precisely trim sheets to the required shape. These subsystems work in coordination with the sheet deposition process, enabling the use of continuous structural material sheets without requiring separate, complex processing steps.
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 production of both large and small structural components with improved load-bearing capacity and reduced material costs by utilizing sheets of composite material with structural components like carbon fiber and resin, allowing for continuous reinforcement throughout the component.
Implementation Method 1
curing a predetermined portion of the sheet
Implementation Method 2
curing a predetermined portion of the sheet
Implementation Method 3
applying an adhesive to the predetermined portion of the preceding processed sheet
Implementation Method 4
bonded together
Data Source
AI summary
An additive manufacturing method comprises: positioning a sheet of composite material; curing a predetermined portion of the sheet; cutting the sheet about the perimeter of the predetermined portion to create a preceding processed sheet; adding a successive sheet of composite material atop and in contact with the preceding processed sheet; curing a predetermined portion of the successive sheet such that the predetermined portions of the successive sheet and the preceding processed sheet are bonded together; and cutting the successive sheet about the perimeter of its predetermined portion to create a subsequent processed sheet. The steps of adding, curing and cutting a successive sheet may be repeated for a plurality of cycles to produce a three-dimensional composite product.