Continuous Composite 3D Printing Without Weak Layer Joints
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Solution Overview
Problem
Current additive manufacturing techniques are slow, require parts to be designed for slicing, result in weak joints, and primarily use homogeneous materials that lack strength and efficiency.
Innovation Solution
A method and apparatus for Continuous Composite Three-Dimensional Printing (CC3D) that uses two materials, a curable liquid as the primary material and a solid strand as the secondary material, extruded together to form composite paths, providing structural stability and functional capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If slicing technique is used to build parts layer by layer, then parts can be manufactured using current additive manufacturing techniques, but the process is slow and parts have weak joints between slices
Solution Approach 1:
The patent applies continuous extrusion of composite material instead of layer-by-layer slicing, eliminating the stop-and-start nature of traditional additive manufacturing. The extruder continuously deposits material along toolpaths, creating uninterrupted structural continuity that eliminates weak interlayer joints while maintaining high manufacturing speed.
Solution Approach 2:
The patent uses composite materials consisting of continuous reinforcement fibers embedded in a matrix material. This composite structure provides both high strength along the fiber direction and rapid manufacturing capability, resolving the contradiction between strength and productivity by integrating structural reinforcement directly into the manufacturing process.
2Strength
If homogeneous materials are used in additive manufacturing, then the manufacturing process is simple, but the parts lack strength and efficiency
Solution Approach 1:
The patent implements composite materials with continuous reinforcement fibers distributed throughout the matrix material. This composite approach significantly enhances part strength and structural efficiency while the extrusion process maintains relative simplicity by continuously depositing the pre-mixed composite material along programmed toolpaths.
Solution Approach 2:
The patent enables variation in material composition and fiber orientation along different toolpaths within the same part. Different regions can have optimized material properties tailored to local structural requirements, allowing high strength where needed while maintaining manufacturing simplicity through a unified extrusion process.
3Adaptability or versatility
If parts are designed to accommodate slicing process, then current additive manufacturing techniques can be used, but design flexibility is reduced
Solution Approach 1:
The patent inverts the traditional approach by eliminating the slicing constraint and using continuous extrusion along arbitrary three-dimensional toolpaths. This allows parts to be designed freely without accommodation to layer boundaries, dramatically increasing design flexibility while the automated extrusion process maintains manufacturing simplicity.
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
Enables faster, stronger, and more flexible part creation with enhanced design and functional possibilities, allowing for integrated circuitry and conductive surfaces.
Implementation Method 1
The primary material is a curable liquid, the best mode being a photosensitive resin
Data Source
AI summary
A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.