Continuous Fiber Composite Printing with Pre-Impregnated Hardener
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Solution Overview
Problem
In traditional additive manufacturing using continuous fiber 3D printing, opaque or high-density fibers can lead to insufficient cure enhancement at the center of fiber bundles, resulting in structures that may lack strength and sag undesirably due to inadequate matrix curing.
Innovation Solution
A method and system for additively manufacturing composite structures by coating continuous reinforcements with a multi-part matrix, including a resin and a catalyst, within a print head, and using a controller to move the print head in multiple dimensions during discharge, ensuring sufficient interaction and curing of the matrix components around the fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fibers with high density or opacity are used, then fiber strength and structural integrity are improved, but matrix curing at the center of fiber bundles becomes insufficient
Solution Approach 1:
The patent divides the matrix material into two separate components (resin and catalyst) that are applied to the fiber bundle at different times and locations. The resin is applied first, followed by the catalyst, allowing each component to penetrate the fiber bundle independently and ensuring complete curing throughout the entire bundle including the center regions.
Solution Approach 2:
The resin component is applied to the fiber bundle before the catalyst is introduced. This preliminary application allows the resin to saturate the fiber bundle first, and then the catalyst is applied to initiate curing, ensuring that the curing reaction occurs throughout the entire bundle including the center regions that would otherwise be difficult to reach.
2Device complexity
If traditional single-component matrix application is used, then process simplicity is maintained, but insufficient curing occurs at the center of fiber bundles
Solution Approach 1:
The matrix application process is segmented into two distinct stages: first applying the resin component, then applying the catalyst component. This segmentation allows for better control of each component's penetration and distribution, ensuring uniform curing throughout the fiber bundle while maintaining a relatively simple two-step process.
Solution Approach 2:
The patent changes the chemical parameters of the matrix system by using a two-component system instead of a single-component system. This allows for independent optimization of resin penetration and catalyst distribution, achieving uniform curing throughout the fiber bundle including the center regions.
3Strength
If high fiber concentration is used, then structural strength is enhanced, but matrix penetration and curing become difficult
Solution Approach 1:
By segmenting the matrix into two components applied sequentially, the system achieves better penetration into high-concentration fiber bundles. The resin component can saturate the dense fiber structure first, and then the catalyst component can diffuse throughout and initiate curing, making impregnation of high-fiber-concentration bundles feasible.
Solution Approach 2:
The resin is applied in advance to saturate the high-concentration fiber bundle, creating a resin-impregnated structure that is then treated with the catalyst. This preliminary impregnation ensures that even densely packed fibers receive adequate matrix material before the curing reaction begins.
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
This approach ensures thorough matrix impregnation and curing of continuous fibers, enhancing the structural strength and stability of the manufactured composite structures by maintaining the fibers' alignment and promoting uniform curing, thereby preventing sagging and ensuring the desired shape and strength.
Implementation Method 1
The first and second matrix components interact to cause hardening of a matrix around the continuous reinforcement
Data Source
AI summary
A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, and coating the continuous reinforcement with a first matrix component inside of the print head. The method may further include coating the continuous reinforcement with a second matrix component, discharging the continuous reinforcement through a nozzle of the print head, and moving the print head in multiple dimensions during the discharging. The first and second matrix components interact to cause hardening of a matrix around the continuous reinforcement.