Continuous-Fiber 3D-Printed Elastomers With Asymmetric Stiffness
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Solution Overview
Problem
Existing 3D printing technologies struggle to produce products with elastic behavior and highly asymmetrical mechanical properties, which are essential for various applications requiring specific tensile moduli and elasticity.
Innovation Solution
A fiber-reinforced, 3D-printed elastic product is developed, comprising at least 50% by weight of a polymer with an average molecular weight of ≥5000 g/mol and 0.5% to 20% by weight of fibers with an aspect ratio of ≥100 and lengths between 3 cm and 1000 cm. The product is produced using the FFF method, ensuring a tensile modulus of ≥1.5 GPa in the direction of the fiber symmetry axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional 3D printing methods are used, then manufacturing flexibility and complexity are improved, but mechanical strength and stiffness are insufficient
Solution Approach 1:
The patent combines polymer material with continuous fiber reinforcement to create a composite material system. The fibers are integrated into the polymer matrix during the FFF printing process, creating a hybrid material that exhibits both the flexibility and complexity enabled by 3D printing and the enhanced mechanical strength provided by the fiber reinforcement, resolving the contradiction between ease of manufacture and mechanical strength
Solution Approach 2:
The patent applies fiber reinforcement selectively in specific regions and orientations within the printed product. By controlling fiber placement, alignment, and concentration in different zones, the material properties are optimized locally to provide enhanced strength where needed while maintaining the overall manufacturing flexibility and design freedom of the 3D printing process
2Ease of manufacture
If isotropic material properties are used, then manufacturing simplicity is improved, but application versatility for asymmetric loads is reduced
Solution Approach 1:
The patent introduces anisotropic material properties through the strategic orientation and arrangement of continuous fibers within the polymer matrix. The fibers are aligned in specific directions to create asymmetric mechanical properties that can be tailored to match asymmetric load conditions, enabling the product to adapt to diverse application requirements while maintaining relative manufacturing simplicity through the FFF process
Solution Approach 2:
The patent creates dynamically adaptable material properties by varying fiber orientation, density, and distribution throughout the printed structure. This allows the product to exhibit different mechanical characteristics in different regions and directions, providing versatility for asymmetric loads while the FFF process maintains manufacturing simplicity through digital control of material deposition
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 product exhibits highly anisotropic mechanical properties, with high strength and stiffness in the direction of the fiber symmetry axis and high elasticity perpendicular to it, enabling successful use in new applications.
Implementation Method 1
the product is at least partially produced by means of a FFF (Fused Filament Fabrication) method
Implementation Method 2
a proportion by weight of ≥0.5% and ≤20% of one or more fibers having an aspect ratio of ≥100 and a length of ≥3 cm and ≤1000 cm, wherein the product, in the region of the fiber reinforcement and in the direction of the fiber symmetry axis, has a tensile modulus of ≥1.5 GPa
Implementation Method 3
a polymer having an average molecular weight of ≥5000 g/mol... The product exhibits highly anisotropic mechanical properties, with high strength and stiffness in the direction of the fiber symmetry axis and high elasticity perpendicular to it
Data Source
AI summary
The present invention relates to a fibre-reinforced 3D-printed elastic product (1, 3, 4, 7, 10, 12), wherein the product comprises a weight proportion of ≥50% of a polymer having a mean molecular weight of ≥5000 g/mol, measured by means of GPC, and a weight proportion of ≥0.5% and ≤20% of one or more fibres having an aspect ratio of ≥100 and a length of ≥3 cm and ≤1000 cm, the product being produced at least in part by means of an FFF (Fused Filament Fabrication) method, and the product having a tensile modulus of ≥1.5 GPa in the region of the fibre reinforcement and in the direction of the fibre symmetry axis. The product also has a tensile modulus, measured according to DIN EN ISO 527-1, of ≤1.2 GPa in the region of the fibre reinforcement and perpendicular to the fibre symmetry axis, and has a yield strength of >5%, measured according to DIN EN ISO 527-1, perpendicular to the fibre symmetry axis.