Additively Manufactured Structures with Conductive Textile Reinforcement

The patent applies composite materials by combining textile substrates (fabric layers) with thermoplastic matrix material to create a fiber-reinforced composite structure. The textile substrates are draped over the additively manufactured structure and consolidated with the thermoplastic matrix through heat and pressure, forming a hybrid composite that leverages the design flexibility of additive manufacturing while gaining the structural strength of traditional composite materials.

The patent employs self-service by using conductive fibers within the textile substrate to generate heat through applied voltage, eliminating the need for external heating systems. The conductive fibers self-generate the thermal energy required for consolidation when electrical current is applied, simplifying the manufacturing process while achieving effective consolidation of the textile substrate with the thermoplastic matrix material.

The patent applies local quality by distributing conductive fibers throughout the textile substrate at specific locations where heating is needed for consolidation. Rather than heating the entire structure uniformly, the conductive fibers are strategically placed to provide localized heating exactly where the textile substrate contacts the thermoplastic matrix, improving consolidation efficiency while minimizing overall energy consumption.