Direct Ink Writing Device for Bias-Controlled Continuous Fiber Composites
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Solution Overview
Problem
Current 3D printing methods for continuous fiber reinforced composite materials, such as fused deposition modeling, struggle to achieve high mechanical properties and intelligent characteristics due to limitations in incorporating continuous fibers and controlling fiber bias positions, leading to suboptimal material properties and high material costs.
Innovation Solution
A direct ink writing device and method that includes a cartridge with a through hole for continuous fibers, a piston with a sealing liquid, and a tensioning system to control fiber bias, allowing for precise placement and extrusion of continuous fibers within the printing matrix, enabling the production of structures with enhanced mechanical and intelligent properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fused deposition modeling process is used for printing continuous fiber reinforced composite materials, then the mechanical properties can be improved, but the fiber bias position cannot be controlled and the process cannot accommodate continuous fibers
Solution Approach 1:
The cartridge is divided into separate functional zones: an upper chamber for containing sealing liquid, a lower chamber for containing printing matrix solution, and a central capillary region for fiber passage. This segmentation allows independent control of fiber positioning and material extrusion, enabling precise fiber bias position control while maintaining mechanical properties.
Solution Approach 2:
A sealing liquid is introduced as an intermediary substance in the upper chamber to control and regulate the continuous fiber during the printing process. The sealing liquid acts as a mediator between the fiber tensioning system and the printing matrix solution, enabling precise control of fiber bias position while maintaining fiber integrity and mechanical properties.
2Manufacturing precision
If sealed cartridge is used for accurate material extrusion, then extrusion accuracy is improved, but continuous fiber cannot pass through the chamber
Solution Approach 1:
The cartridge is segmented into distinct functional regions: an upper chamber sealed with sealing liquid for precise material control, a lower chamber for printing matrix solution storage, and a central capillary pathway for continuous fiber passage. This segmentation allows the sealed cartridge to maintain extrusion accuracy while providing a dedicated fiber passage that accommodates continuous fibers without compromising sealing integrity.
Solution Approach 2:
Different regions of the cartridge are assigned different functional qualities: the upper chamber provides sealed containment for material precision, the capillary region provides open passage for fiber transmission, and the lower chamber provides solution storage. This local differentiation of functional qualities allows the cartridge to simultaneously achieve accurate extrusion and continuous fiber compatibility.
3Loss of substance
If small amount of material is prepared for direct ink writing, then material cost is reduced, but mechanical properties of cured matrix are insufficient
Solution Approach 1:
The invention creates a composite material system combining printing matrix solution with continuous fibers and sealing liquid. The continuous fibers serve as reinforcement materials that dramatically improve the mechanical properties of the cured matrix, while the sealing liquid provides additional structural support. This composite approach allows small material quantities to be used while achieving superior mechanical properties through fiber reinforcement.
Solution Approach 2:
The sealing liquid acts as an intermediary reinforcement substance that complements the continuous fibers. Together with the fibers, the sealing liquid provides structural support to the cured matrix, enabling the use of minimal printing matrix solution while maintaining adequate mechanical properties. The sealing liquid mediates between the fiber reinforcement and the matrix solution, creating a synergistic effect.
4Strength
If continuous fibers are added to improve mechanical properties, then strength is improved by one or more orders of magnitude, but the fiber bias position cannot be controlled in existing processes
Solution Approach 1:
The system incorporates feedback control through the sealing liquid level monitoring and adjustment mechanism. The sealing liquid level in the upper chamber provides a visual and physical indicator of fiber position and material flow conditions, enabling real-time adjustment of printing parameters to maintain precise fiber bias position control while maximizing mechanical property enhancement from the continuous fibers.
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
The solution enables the production of composite materials with controlled fiber bias positions, improving mechanical strength and intelligent characteristics, suitable for applications in aerospace and metamaterials, while reducing material costs and optimizing printing parameters.
Implementation Method 1
a piston 18 is arranged in the cartridge 20, the piston 18 is provided with an upper chamber for containing sealing liquid 17 and a capillary for a continuous fiber 10 to pass through
Implementation Method 2
the piston 18 is fixedly connected to a connecting shaft 9, the connecting shaft 9 is connected to an external vertical moving device through a rotary bearing 8, and is connected to a motor belt wheel 1 of a motor 3 through a belt wheel and a synchronous belt 2
Implementation Method 3
the continuous fiber 10 led out through the bore is connected to a tensioning wheel 11
Implementation Method 4
the prepared material generally only needs to meet certain shear thinning characteristics and rapid curing capability
Data Source
AI summary
A direct ink writing device and method for a bias-controllable continuous fiber reinforced composite material are provided. The device includes a cartridge fixed by an external device, a bottom of the cartridge is connected to a nozzle. A piston is arranged in the cartridge, the piston is provided with a chamber for containing sealing liquid and a capillary for a continuous fiber to pass through. The centers of an inner circumference and an outer circumference of the cartridge do not coincide with each other. The bias position of the continuous fiber in the composite material is achieved using the piston, and each filament of composite material is printed in steps of rotation, extrusion, revolution and curing. A structure produced according to the disclosure has high mechanical properties and outstanding intelligent properties, and the bias position of the continuous fiber material in the structure can be accurately adjusted.