Additive Manufacturing Composite Parts Continuous Fiber Deposition
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Solution Overview
Problem
Conventional composite manufacturing methods result in heavier parts due to laminar construction, where not all reinforcement fibers are oriented along the applied forces, and limit advanced structural designs.
Innovation Solution
A system for additively manufacturing composite parts by depositing a continuous flexible line composed of a non-resin component and a thermosetting-resin component, with a delivery guide and feed mechanism to orient the composite material in desired orientations, allowing for customization of properties throughout the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laminar construction with multiple plies of composite material is used, then the part can be manufactured using conventional techniques, but the weight of the finished part increases
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from laminar layering to continuous fiber deposition. The additive manufacturing system deposits reinforcement fibers continuously in the desired orientation pattern, eliminating the need for multiple laminar plies and reducing overall part weight while maintaining structural integrity.
Solution Approach 2:
The invention transitions from two-dimensional laminar construction to three-dimensional continuous fiber architecture. Fibers are deposited in complex 3D paths that follow stress trajectories, allowing optimization of material orientation in multiple dimensions rather than being constrained to flat laminar layers.
2Ease of manufacture
If laminar construction with multiple plies is used, then conventional manufacturing techniques can be applied, but the reinforcement fibers cannot be optimally oriented along the direction of applied forces
Solution Approach 1:
The patent applies local quality by varying the fiber orientation at different locations throughout the part. The additive manufacturing system deposits fibers with orientations that are locally optimized to match the principal stress directions at each specific location, rather than using uniform laminar orientations throughout the entire part.
Solution Approach 2:
The invention introduces dynamics into the fiber orientation scheme. Instead of static laminar orientations, the system dynamically adjusts fiber deposition angles and paths to follow the varying stress trajectories through the part structure, optimizing strength-to-weight ratio.
3Ease of manufacture
If laminar construction techniques are used, then conventional composite manufacturing can be implemented, but advanced structural designs are limited
Solution Approach 1:
The additive manufacturing system provides universality by being capable of manufacturing diverse complex structural designs that cannot be achieved with conventional laminar techniques. The system can deposit fibers in arbitrary 3D paths, enabling the creation of optimized structural topologies, variable stiffness regions, and integrated features within a single manufacturing process.
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 the creation of lightweight composite parts with tailored properties by ensuring reinforcement fibers are optimally oriented, facilitating the implementation of complex structural designs.
Implementation Method 1
The thermosetting-resin component comprises a first part of a thermosetting resin and a second part of a thermosetting resin
Data Source
Figure 1
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AI summary
A method for additively manufacturing a composite part (102) comprises: applying a thermosetting resin (252) to a non-resin component (108) to create a continuous flexible line (106) by pulling the non-resin component (108) through a first resin-part applicator (236), in which a first quantity of a first part (253) of the thermosetting resin (252) is applied to the non-resin component (108), and by pulling the non-resin component (108) through a second resin-part applicator (237), in which a second quantity of second part (255) of the thermosetting resin (252) is applied to at least a portion of the first quantity of the first part (253) of the thermosetting resin (252), applied to the non-resin component (108); routing the continuous flexible line (106) into a delivery guide (112); and depositing, via the delivery guide (112), a segment (120) of the continuous flexible line (106) along a print path (122).