FDM 3D Printing with Embedded Solid Fiber Twisting Control

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Solution Overview

Problem

Existing 3D printing methods, particularly FDM, face challenges in embedding long fibers due to twisting and torque issues, leading to fibers being pulled out of layers or protruding from the printed item, especially with thicker fibers, which limits their use in applications like electrical or optical connections.

Innovation Solution

A method and system for 3D printing that involves feeding elongated solid fibers, such as carbon fibers or conductive wires, through a FDM printer nozzle, using a separate feeder for thicker fibers and controlling their rotation to prevent twisting, allowing for stable embedding of fibers within the printed layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If long fibers are embedded in FDM 3D printing, then the mechanical strength and functionality of the printed item is improved, but the fibers twist and protrude from layers due to torque during printing

Engineering Contradiction:

Improvemechanical strengthVSAvoidfiber embedding precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The fiber feeding system is divided into separate components: a fiber reel, a tensioning mechanism, and a guide system. This segmentation allows independent control of fiber tension and positioning, preventing twisting while maintaining embedding precision throughout the printing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fiber is pre-tensioned before entering the printing nozzle using a tensioning mechanism. This preliminary action ensures the fiber remains straight and properly positioned during deposition, preventing torque-induced twisting and layer protrusion before the fiber is embedded in the printed material.

Inventive Principle:

Principle #10Preliminary action

2Strength

If thicker fibers are used to improve structural integrity, then the mechanical properties are enhanced, but the fibers become more prone to twisting and pulling out during printing

Engineering Contradiction:

Improvestructural integrityVSAvoidfiber stability during printing

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

A tensioning mechanism applies counter-tension to thicker fibers during feeding, balancing the torque forces that cause twisting. This counteracting force maintains fiber stability and prevents pulling out, allowing thicker fibers to be reliably embedded without compromising printing reliability.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Solution Approach 2:

A guide mechanism acts as an intermediary between the fiber source and the printing nozzle, controlling fiber trajectory and tension. This intermediary component stabilizes thicker fibers during transit and deposition, preventing twisting and ensuring reliable embedding in the printed structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Duration of action of stationary object

If fibers are fed through the printer nozzle along with molten material, then continuous fiber embedding is achieved, but the fibers twist due to torque from the extrusion process

Engineering Contradiction:

Improvecontinuous fiber embeddingVSAvoidtorque-induced twisting

Core Design Contradiction:

Duration of action of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The fiber feeding path is extracted and separated from the molten material extrusion path. Fibers are fed through a dedicated guide system that enters the nozzle separately from the material stream, eliminating the torque interaction between extrusion forces and fiber positioning, thus preventing twisting while maintaining continuous embedding.

Inventive Principle:

Principle #2Taking out (Extraction)

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 stable embedding of long fibers in 3D printed items, facilitating their use in optical and electrical applications by preventing twisting and ensuring fibers remain embedded throughout the printing process, even with thicker fibers.

Implementation Method 1

a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. Possibly, (for thermoplastics for example) the filament is melted and extruded before being laid down

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

the fiber providing unit is further configured to control a rotation of the elongated solid fiber provided to the printer nozzle around an axis (C1) of elongation of the elongated solid fiber

Methodology Applied

Scientific EffectRotation control:

Implementation Method 3

co-depositing, during a printing stage, the 3D printable material and the elongated solid fiber via the printer nozzle, to provide the 3D item comprising 3D printed material with the elongated solid fiber embedded therein

Methodology Applied

Scientific EffectEmbedding:

Data Source

PatentUS12134225B2Method for 3D printing a 3D item

Publication Date: 2024.11.05 SIGNIFY HOLDING BV

AI summary

The invention provides a method comprising 3D printing a 3D item (1), the method comprising co-depositing during a printing stage 3D printable material (201) and an elongated solid fiber (310) with a fused deposition modeling 3D printer (500) via a single nozzle (502), to provide the 3D item (1) comprising 3D printed material (202) with the elongated solid fiber (310) embedded therein.