Fiber-Reinforced FDM Assembly for Cross-Layer Axial Strength
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Solution Overview
Problem
Carbon fiber-reinforced parts manufactured using additive manufacturing do not exhibit enhanced axial strength in directions non-parallel to the deposition direction of thermoplastic material.
Innovation Solution
The method involves displacing reinforcement fibers across multiple layers using a needle apparatus or a second FDM deposition head to extend fibers beyond two layers, enhancing axial strength in multiple directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement fibers are deposited within single layers of thermoplastic material, then the manufacturing process is simple, but the axial strength in directions non-parallel to deposition direction is not enhanced
Solution Approach 1:
The patent transitions from two-dimensional planar fiber deposition to three-dimensional fiber placement by inserting a needle apparatus vertically through multiple layers. This allows reinforcement fibers to extend across multiple layers in the vertical dimension, enhancing axial strength in directions non-parallel to the deposition direction while maintaining a relatively simple modified FDM process.
Solution Approach 2:
The needle apparatus serves as an intermediary tool that enables the transfer and placement of reinforcement fibers across multiple thermoplastic layers. The needle inserts through the layers and deposits fibers in the vertical dimension, acting as a mediator between the fiber source and the multi-layer structure, thereby achieving enhanced axial strength without complex multi-axis deposition systems.
2Reliability
If reinforcement fibers are confined to single layers, then the deposition process is straightforward, but the structural integrity across layers is limited
Solution Approach 1:
The invention improves structural integrity by adding the vertical dimension to fiber placement. The needle apparatus inserts through multiple layers vertically, allowing reinforcement fibers to span across layers in the Z-direction, thereby creating continuous load paths and enhancing structural integrity without requiring complex multi-axis deposition equipment.
Solution Approach 2:
The method employs preliminary action by first depositing thermoplastic layers with embedded fibers, then subsequently inserting the needle apparatus to reposition and extend fibers across additional layers. This two-stage approach allows for improved structural integrity while maintaining ease of manufacture, as the fiber displacement occurs after the basic layer deposition is complete.
3Strength
If fibers extend across multiple layers using needle insertion, then axial strength in multiple directions is enhanced, but the device complexity increases
Solution Approach 1:
The needle apparatus acts as a simple intermediary device that achieves complex fiber placement functionality. By using a straightforward needle insertion and withdrawal mechanism, the system enables fibers to extend across multiple layers vertically, enhancing vertical axial strength without requiring complex multi-axis deposition systems or sophisticated control mechanisms.
Solution Approach 2:
The FDM deposition head and needle apparatus work in a self-service manner where the needle is inserted into the deposited layers and automatically displaces fibers along its path. The thermoplastic material itself facilitates the process by providing a matrix that holds and guides the fibers during needle insertion, reducing the need for additional complex positioning or control systems.
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 method significantly enhances the vertical axial strength of the component by allowing reinforcement fibers to extend across multiple layers, thereby improving structural integrity.
Implementation Method 1
depositing via a fused-deposition manufacturing (FDM) deposition head
Implementation Method 2
depositing via a fused-deposition manufacturing (FDM) deposition head a plurality of layers of a filament
Data Source
AI summary
Methods and assemblies for additive manufacturing portions of components with enhanced strength are provided. The assemblies comprise a first deposition head and an apparatus for causing one or more reinforcement fibers to extend more than two layers within previously-deposited layers of build material. The first deposition head is configured to deposit a plurality of layers of a filament comprising a reinforcement fiber and thermoplastic material. The apparatus may comprise a needle point configured to be inserted into the plurality of layers to displace the reinforcement fiber so that it extends two or more of the plurality of layers. The apparatus may additionally or alternatively comprise a second deposition head having a needle tip configured to be inserted into the plurality of layers to inject a length of a second filament comprising thermoplastic material and a reinforcement fiber so that the reinforcement fiber of the second filament extends two or more layers of the plurality of layers of the first filament.