Additive Manufacturing of Composite Parts via Continuous Flexible Line
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Solution Overview
Problem
Conventional composite part manufacturing methods, such as laminar construction, result in increased weight due to non-optimally oriented reinforcement fibers and limitations in implementing advanced structural designs.
Innovation Solution
A system and method for additively manufacturing composite parts using a delivery guide to deposit a continuous flexible line composed of a non-resin component and a thermosetting-resin component, with sequential application of thermosetting resin parts to create a composite material that can be oriented as desired, allowing for customized properties throughout the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If laminar construction methods are used to manufacture composite parts, then the manufacturing process is simple and conventional, but the reinforcement fibers are not optimally oriented along the direction of force, resulting in increased weight
Solution Approach 1:
The continuous flexible line is segmented into discrete deposits along the print path, with each segment containing fibers oriented in the optimal direction for that specific location. This segmentation allows independent optimization of fiber orientation in each deposited segment while maintaining overall structural integrity
Solution Approach 2:
The system implements local quality by varying the fiber orientation, material composition, and structural properties of the continuous flexible line at different locations along the print path. Each location receives a customized deposit tailored to the local structural requirements and load conditions
2Adaptability or versatility
If laminar construction with multiple plies is used, then conventional manufacturing techniques are applied, but advanced structural designs cannot be implemented due to inherent limitations
Solution Approach 1:
The system employs dynamic control of the deposition process, where the delivery guide can be moved relative to the surface and the print path can be stationary relative to the surface, allowing adaptive adjustment of deposition parameters, speed, and positioning to accommodate complex geometries and advanced structural designs
Solution Approach 2:
The invention transitions from traditional two-dimensional laminar layering to three-dimensional additive manufacturing, depositing continuous flexible line material in controlled patterns that build complex structures in multiple dimensions, enabling advanced designs that are impossible with conventional laminar techniques
3Reliability
If continuous flexible line with optimized fiber orientation is deposited, then weight is reduced and performance is enhanced, but the manufacturing process requires sequential application of resin parts and precise delivery control
Solution Approach 1:
The system performs preliminary action by pre-orienting the reinforcement fibers within the continuous flexible line before deposition, and by pre-heating or pre-processing the resin components. The delivery guide is positioned and calibrated in advance to ensure precise deposition along the intended print path, reducing the need for complex post-processing
Solution Approach 2:
The continuous flexible line acts as an intermediary carrier that transports the reinforcement fibers in the desired orientation to the deposition point. The resin components serve as intermediaries that bind the fibers together and facilitate the layering process, simplifying the overall manufacturing complexity while maintaining structural performance
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 production of lightweight composite parts with tailored properties by optimizing fiber orientation and allowing for more complex structural designs, reducing weight and enhancing performance.
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
AI summary
A system for additively manufacturing a composite part comprises a delivery guide, movable relative to a surface. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting-resin component. The thermosetting-resin component comprises a first part and a second part. The non-resin component comprises a first element and a second element. The system further comprises a first resin-part applicator, configured to apply the first part to the first element, and a second resin-part applicator, configured to apply the second part to the second element. The system also comprises a feed mechanism, configured to pull the first element through the first resin-part applicator, to pull the second element through the second resin-part applicator, and to push the continuous flexible line out of the delivery guide.