Additive Manufacturing Fiber Orientation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing methods are limited in using medium length reinforcement fibers and lack the ability to control the orientation of fibers within the additive manufactured parts, which restricts the enhancement of mechanical properties.
Innovation Solution
A method and apparatus for depositing and orienting reinforcement fibers within layers of build material in an additive manufacturing machine, using mechanical straighteners and electromagnetic fields to control the orientation of fibers, allowing for the embedding of longer fibers and precise re-orientation between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If short fibers are used in additive manufactured parts, then the manufacturing process is simpler and easier to control, but the mechanical properties such as strength and stiffness are limited
Solution Approach 1:
The patent applies preliminary action by pre-mixing the reinforcement fibers with the polymer material before the additive manufacturing process. This pre-mixing ensures uniform fiber distribution throughout the material, allowing medium length fibers to be effectively incorporated without requiring complex in-situ fiber placement mechanisms during printing. The fibers are already positioned and oriented in the material prior to deposition, simplifying the manufacturing process while achieving enhanced mechanical properties.
2Strength
If medium length reinforcement fibers are embedded in additive manufactured parts, then the strength and stiffness are substantially increased, but the ability to control fiber orientation is limited
Solution Approach 1:
The patent applies local quality by implementing variable fiber orientation control at different locations and layers of the additive manufactured part. The system adjusts fiber orientation parameters locally based on the specific structural requirements of each region, allowing optimized mechanical properties in critical areas while maintaining manufacturing feasibility. This localized control approach enables precise orientation management for medium length fibers without requiring uniform control throughout the entire part.
Solution Approach 2:
The patent applies dynamics by implementing a dynamic fiber orientation control system that can adjust fiber orientation parameters during the additive manufacturing process. The system dynamically modifies fiber placement angles and orientations based on real-time process conditions and layer-by-layer construction requirements, enabling precise control over medium length fiber alignment to achieve enhanced mechanical properties in specific directions.
3Strength
If longer fibers are used to enhance mechanical properties, then the strength and thermal resistance improve, but the fibers create anisotropy and warping issues in larger prints
Solution Approach 1:
The patent applies parameter changes by systematically varying fiber orientation parameters across different layers and regions of the additive manufactured part. By changing fiber orientation angles and patterns as a controlled parameter, the system optimizes mechanical properties while compensating for warping tendencies. This parameter variation approach allows medium length fibers to provide enhanced strength and thermal resistance without creating excessive anisotropy or warping in larger prints.
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 creation of additive manufactured parts with enhanced mechanical properties by allowing selective control of fiber orientation, improving strength, stiffness, and thermal resistance, and enabling the use of longer fibers without the limitations of anisotropy.
Implementation Method 1
re-orient the reinforcement fibers within the layer of build material with an electromagnetic field
Data Source
AI summary
A method of forming an additive manufactured component comprises depositing a first layer of build material on a build platform within an additive manufacturing machine, depositing reinforcement fibers into the first layer of build material, orienting the reinforcement fibers within the first layer of build material, lowering the build platform, depositing a second layer of build material on top of the first layer of build material, depositing reinforcement fibers into the second layer of build material, and orienting the reinforcement fibers within the second layer of build material.