Conductive Textile Reinforcement for Additively Manufactured Structures

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Solution Overview

Problem

Additively manufactured structures exhibit inherent weakness due to poor layer-to-layer adhesion, necessitating techniques for strengthening and reinforcing these structures.

Innovation Solution

A method involving draping a textile substrate with conductive fibers over the structure and applying an electric current to heat the thermoplastic matrix material for consolidation, forming a thermoplastic composite.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional additive manufacturing is used, then manufacturing complexity is reduced, but structural integrity deteriorates due to poor layer-to-layer adhesion

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining thermoplastic matrix material with textile substrates containing conductive fibers. This creates a hybrid structure where the thermoplastic provides base structural properties while the textile substrate with conductive fibers enhances strength and enables electrical heating for improved layer adhesion, directly resolving the structural integrity issue without significantly increasing manufacturing complexity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes parameter changes by applying electric current to conductive fibers to heat the thermoplastic matrix material to specific temperature ranges. This thermal parameter change enables the thermoplastic to soften and bond with the textile substrate, improving layer-to-layer adhesion and overall structural integrity through controlled thermal processing

Inventive Principle:

Principle #35Parameter changes

2Strength

If textile substrate with conductive fibers is applied and electric current is applied, then layer-to-layer adhesion is improved, but energy consumption increases

Engineering Contradiction:

Improvelayer-to-layer adhesionVSAvoidelectric current energy

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent implements self-service by using the conductive fibers within the textile substrate as both structural reinforcement elements and heating elements. The same conductive fibers that provide mechanical strength also serve as resistive heating elements when electric current is applied, eliminating the need for separate heating mechanisms and reducing overall energy consumption

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent leverages phase transitions by applying electric current to conductive fibers to heat the thermoplastic matrix material from a solid state to a softened state suitable for bonding. This controlled phase transition enables the thermoplastic to adhere to the textile substrate, improving layer-to-layer adhesion through thermal energy that is efficiently delivered via the conductive fiber network

Inventive Principle:

Principle #36Phase transitions

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

Enhances the structural integrity of additively manufactured structures by creating a fiber-reinforced composite, eliminating the need for molds and robotic end effectors, enabling complex designs and mass customization.

Implementation Method 1

applying an electric current to at least one conductive fiber of the one or more conductive fibers to heat the thermoplastic matrix material of the additively manufactured structure

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250282097A1Methods and systems for reinforcing additively manufactured structures

Publication Date: 2025.09.11 THE BOEING CO

AI summary

A method for reinforcing an additively manufactured structure includes draping a textile substrate including one or more conductive fibers over at least a portion of a surface of the additively manufactured structure. The additively manufactured structure includes a thermoplastic matrix material. An electric current is applied to a conductive fiber to heat the thermoplastic matrix material of the additively manufactured structure for consolidation of the textile substrate with the thermoplastic matrix material to form a thermoplastic composite on the surface. A system for reinforcing an additively manufactured structure includes a fabrication tool set, an electrical power source and a control device. The control device and the electrical power source apply the electric current to the conductive fiber to heat the thermoplastic matrix material for consolidation of the textile substrate with the thermoplastic matrix material to form a thermoplastic composite.