Continuous Fiber Tool Paths for Residual Tension in 3D Printing
Solution Overview
Problem
Current additive manufacturing technologies, such as traditional FDM, face limitations in controlling the orientation and tension of continuous fibers within structures, which affects the strength and stability of the final product.
Innovation Solution
A system and method that uses an additive manufacturing machine controlled by a processor to determine and generate tension vectors within a structure by arranging continuous fibers through sequentially executable tool paths, allowing for residual tension to be created in the fibers during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional FDM additive manufacturing is used to deposit overlapping layers of material, then the manufacturing process is simple and widely applicable, but the strength and stability of the final structure are limited by the matrix-dependent properties and layer-by-layer construction
Solution Approach 1:
The patent applies composite materials by embedding continuous fibers within the matrix material discharged from the print head. This combination of continuous fibers and matrix creates a composite structure that significantly enhances strength and stability beyond what traditional thermoplastic alone can achieve, directly resolving the contradiction between simplicity and strength.
Solution Approach 2:
The patent applies preliminary action by pre-planning the fiber orientation and tension distribution through computational design before manufacturing. The system determines optimal fiber paths and tension vectors in advance, then guides the additive manufacturing process to follow these predetermined plans, achieving high strength without requiring complex real-time control during manufacturing.
2Strength
If continuous fibers are embedded within material discharging from the print head, then the strength of the structure is multiplied beyond matrix-dependent strength, but the control over fiber orientation and tension distribution becomes difficult
Solution Approach 1:
The patent applies feedback by implementing a closed-loop control system that monitors fiber tension and orientation during the manufacturing process. Sensors detect actual fiber placement and tension levels, and this information feeds back to the control system to adjust subsequent fiber deposition parameters, ensuring precise control over fiber orientation and tension distribution throughout the structure.
Solution Approach 2:
The patent applies dynamics by making the fiber deposition process adaptive and variable. The system dynamically adjusts fiber feed rate, print head speed, and tension application based on real-time conditions and the predetermined tension vector map. This dynamic control allows precise manipulation of fiber orientation and tension distribution to match the optimal design parameters.
3Ease of manufacture
If a cure enhancer is activated to initiate and complete curing of the matrix immediately upon exiting the print head, then unsupported structures can be fabricated in free space, but the control over residual tension in fibers during manufacture becomes challenging
Solution Approach 1:
The patent applies preliminary action by pre-calculating and programming the tension vector distribution and fiber placement strategy before manufacturing begins. The system determines the optimal tension state for each fiber segment in advance and guides the print head to apply these tensions during deposition. This pre-planning enables immediate curing in free space while maintaining precise control over residual tension through predetermined parameters.
Solution Approach 2:
The patent applies mechanics substitution by replacing manual or mechanical tension control methods with a computer-controlled system. The processor-based control system calculates and manages fiber tension vectors digitally, substituting complex mechanical tensioning mechanisms with software-driven control that can precisely manage residual tension during immediate curing operations in free space.
Data Source
AI summary
A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to determine a plurality of tension vectors to be generated within the structure, and to generate a plan for manufacturing the structure. The plan may include tool paths that arrange continuous fibers within the structure to generate the plurality of tension vectors. The processor may also be configured to execute the computer-executable instructions to cause the additive manufacturing machine to follow the plan and manufacture the structure.