Fiber Reinforced Composite Sandwich Structure Additive Manufacturing
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Solution Overview
Problem
Current production processes for complex composite structures like skin-honeycomb sandwich structures suffer from low automation, low accuracy, high labor intensity, and poor quality stability, leading to inefficiencies and increased costs.
Innovation Solution
An additive manufacturing method and device that uses a supporting mold printed with water-soluble resin, fiber automatic placement assisted by laser heating and constant force rolling, and a honeycomb structure printed using fused deposition, enabling improved automation, accuracy, and integration of skin-honeycomb sandwich layer structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual preparation and assembly methods are used for skin-honeycomb sandwich structures, then flexibility in handling complex geometries is improved, but automation level and manufacturing precision deteriorate
Solution Approach 1:
The patent replaces manual mechanical operations with an automated additive manufacturing system that uses computer-controlled deposition of fiber-reinforced materials and automated placement of honeycomb cores, eliminating manual labor while maintaining the ability to handle complex geometries through digital modeling and automated path planning
Solution Approach 2:
The patent changes the manufacturing parameters from discrete manual assembly operations to continuous automated material deposition processes, allowing precise control of material placement, layer thickness, and structural geometry through programmable parameters, thereby achieving both high automation and adaptability to complex designs
2Adaptability or versatility
If manual alignment and bonding processes are used, then adaptability to design changes is improved, but manufacturing precision and quality stability deteriorate
Solution Approach 1:
The patent replaces manual alignment and bonding operations with automated computer-controlled positioning systems and robotic placement mechanisms that achieve precise alignment through digital coordinates and programmable motion control, eliminating human error while maintaining design flexibility through software-based modifications
Solution Approach 2:
The patent uses digital 3D models as precise copies of the final product geometry to guide automated manufacturing processes, ensuring that every component is manufactured according to exact digital specifications rather than manual measurements, thereby achieving high precision while allowing rapid design iterations through digital model updates
3Ease of repair
If traditional assembly methods with multiple steps are used, then ease of repair and modification is improved, but productivity and manufacturing time deteriorate
Solution Approach 1:
The patent merges multiple separate manufacturing steps (skin fabrication, honeycomb core placement, bonding, and finishing) into a single integrated additive manufacturing process that produces the complete sandwich structure in one continuous automated operation, dramatically increasing productivity while maintaining the ability to modify designs through digital model changes before manufacturing
4Adaptability or versatility
If manual labor-intensive processes are used, then adaptability to complex geometries is improved, but labor intensity and production costs deteriorate
Solution Approach 1:
The patent replaces labor-intensive manual operations with an automated additive manufacturing system that uses computer-controlled material deposition and robotic manipulation to fabricate complex geometries, eliminating the need for skilled manual labor while maintaining the capability to produce intricate structures through digital design and automated path planning
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 enhances the automation level, reduces labor and production costs, and improves the mechanical properties and quality stability of skin-honeycomb sandwich layer structure parts, making them suitable for aerospace and other applications.
Implementation Method 1
a supporting mold is printed through a fused deposition additive manufacturing process and by using a water-soluble resin material
Implementation Method 2
a fiber automatic placement process is assisted through laser heating and constant force rolling
Implementation Method 3
a honeycomb structure is printed and formed on the surface of the lower skin structure through the fused deposition additive manufacturing process and by using the fiber-reinforced composite material
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
The disclosure belongs to the technical field related to the additive manufacturing of composite materials and discloses an additive manufacturing method and manufacturing device for a complex structure of fiber-reinforced composite material. The complex structure is a skin-honeycomb sandwich layer structure, and the manufacturing method includes: printing a supporting mold through a fused deposition process and by using a water-soluble resin material; assisting a fiber automatic placement process through laser heating and constant force rolling and performing placement on the supporting mold to form a lower skin structure by using a fiber-reinforced pre-preg material; printing and forming a honeycomb structure on a surface of the lower skin structure through the fused deposition process and by using the fiber-reinforced composite material; performing placement on the honeycomb structure again to form an upper skin structure; and removing the supporting mold to obtain the skin-honeycomb sandwich layer structure. The disclosure is capable of achieving moldless and rapid manufacturing of the complex structure of the fiber-reinforced composite material such as an aerospace skin-honeycomb sandwich layer. Compared to a conventional manufacturing method, part manufacturing time and costs are significantly decreased while ensuring the mechanics properties.