Continuous Fiber Build Material for Delamination-Resistant 3D Printing
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Solution Overview
Problem
Existing 3D printing techniques for fabricating fiber-reinforced composite structures face challenges such as material wastage, labor-intensiveness, difficulty in automating complex shapes, and delamination issues due to inconsistent stiffness of fibers and matrix materials, particularly in quasi-1D structures, leading to inefficient and time-consuming production of medical devices for musculoskeletal and dental disorders.
Innovation Solution
A multi-purpose, structurally optimized continuous fiber-reinforced build material with braided segments and additional elements, allowing for improved load distribution and mechanical interconnection, which can be used in both conventional molding and additive manufacturing processes, including 3D printing, to reduce the need for supporting structures and enhance the production of complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional 3D printing techniques with particles or short chopped fibers are used, then the manufacturing process is simple, but the mechanical properties are limited and material strength is insufficient
Solution Approach 1:
The patent uses continuous fibers embedded in a polymer matrix to create composite build material. The continuous fibers provide superior mechanical strength compared to particles or short chopped fibers, while the polymer matrix binds the fibers together and transfers loads between them, achieving both high strength and manufacturability
Solution Approach 2:
The patent changes the fiber length parameter from short chopped or particle scale to continuous fiber scale, and embeds these continuous fibers in a polymer matrix. This parameter change transforms the material from having limited mechanical properties to exhibiting enhanced strength and stiffness while remaining processable through extrusion
2Loss of substance
If TFP technique with continuous fiber rovings stitched to base material is used, then material wastage is reduced, but the process is time-consuming and mostly oriented on 2D shapes
Solution Approach 1:
The patent transitions from 2D TFP stitching to 3D continuous fiber deposition. The extrusion system deposits continuous fibers in three-dimensional space directly following the toolpath, enabling complex 3D geometries without the time-consuming layer-by-layer stitching process of traditional TFP
Solution Approach 2:
The patent maintains continuous fiber deposition throughout the manufacturing process. The extrusion system continuously feeds and deposits fibers along the toolpath without interruption, eliminating the stop-and-stitch process of TFP and significantly reducing fabrication time while maintaining material efficiency
3Extent of automation
If FDM technique with single continuous reinforcing fiber or bundle is used, then the process is automated, but delamination occurs due to inconsistent stiffness of fibers and matrix materials in quasi-1D structures
Solution Approach 1:
The patent creates a composite build material with continuous fibers embedded in a polymer matrix. This composite structure provides consistent mechanical properties and stiffness throughout the deposited material, preventing delamination in quasi-1D structures while maintaining automation through extrusion-based deposition
Solution Approach 2:
The patent ensures homogeneous distribution of continuous fibers within the polymer matrix. This homogeneity creates consistent mechanical properties throughout the material, eliminating the stiffness inconsistencies that cause delamination in traditional FDM approaches while maintaining automated extrusion processing
4Strength
If standard SLA machines with woven or non-woven fabric layers are used, then some reinforcement is achieved, but applications are highly limited and real advantages over traditional mass production are not present
Solution Approach 1:
The patent moves from 2D fabric layer placement to 3D continuous fiber deposition. The extrusion system can deposit fibers in complex three-dimensional paths, enabling applications beyond flat laminates including curved surfaces, hollow structures, and complex geometries that are impossible with traditional 2D fabric reinforcement
Solution Approach 2:
The patent introduces dynamic adaptability through programmable toolpath generation. The system can dynamically adjust fiber deposition patterns, layer orientations, and geometric complexity based on computational design, enabling versatile applications across different industries rather than being limited to simple 2D shapes
Data Source
AI summary
A continuous fiber-reinforced build material for additive manufacturing (AM) of fiber-reinforced composite (FRC) structures, a machine for the preparation of the build material, and use of the build material for manufacturing of three-dimensional (3D) FRC end-product devices, such as medical devices for management of musculoskeletal and dental disorders.