Fiber-Reinforced Feedstock Line Rigidizing for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing processes face challenges with feedstock materials like glutinous substances, elongate fibers, and uncured resins, which can clog or damage print heads due to their properties, making it difficult to handle and deposit these materials effectively.
Innovation Solution
A system comprising a rigidizing mechanism to transform the resin from a partially uncured state to a more rigid state, a delivery guide to deposit the feedstock line, a de-rigidizing mechanism to revert it to a less rigid state for deposition, and a curing mechanism to cure the resin in situ, ensuring the feedstock line's integrity and flexibility for three-dimensional printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the resin is kept in a partially uncured state for flexibility, then the feedstock line can be coiled and handled, but it becomes too flexible and tacky to feed through the delivery guide without gumming up
Solution Approach 1:
The patent applies parameter changes by transforming the resin's physical state through temperature control. The resin is cooled to increase rigidity for feedability, then heated to restore flexibility for deposition. This dynamic parameter adjustment resolves the contradiction between needing flexibility for handling and rigidity for feedability.
Solution Approach 2:
The system dynamically adjusts the resin's rigidity state based on operational requirements. The resin transitions from a flexible coiled state to a rigid feedable state, then back to a flexible depositable state. This dynamic state change allows the same material to satisfy opposing requirements at different stages of the process.
2Ease of operation
If the resin is rigidized for feeding through the delivery guide, then the feedstock line can be advanced without damage, but it becomes too rigid for three-dimensional deposition
Solution Approach 1:
The patent uses parameter changes by controlling temperature to modulate resin rigidity. Heating restores flexibility for 3D deposition after cooling provided rigidity for feeding. This reversible parameter transformation allows the material to sequentially satisfy contradictory requirements.
Solution Approach 2:
The system employs dynamic state transitions where the resin alternates between rigid and flexible states based on process stage. The rigid state enables mechanical feeding, while the flexible state enables conformal 3D deposition, with transitions controlled by thermal processing.
3Strength
If elongate fibers are used to reinforce the feedstock line, then structural integrity is improved, but the fibers may kink, break, or buckle during handling and feeding
Solution Approach 1:
The patent applies parameter changes by using temperature-controlled rigidity adjustment to protect fibers during handling. The rigid state prevents fiber buckling during feeding, while the flexible state allows gentle coiling and storage. This dynamic rigidity control preserves fiber integrity throughout the process cycle.
Solution Approach 2:
The system provides beforehand cushioning by pre-rigidizing the feedstock line before fiber-prone operations like feeding through the delivery guide. This preventive rigidity increase protects vulnerable fibers from mechanical damage before it can occur.
4Ease of operation
If uncured or partially cured resin is used in the feedstock line, then the material remains workable, but it gradually cures inside the print head causing progressive clogging
Solution Approach 1:
The patent uses parameter changes by controlling temperature to manage resin cure rate. Cooling slows curing to maintain workability during storage and feeding, while controlled heating enables deposition. This thermal parameter management prevents premature curing in the print head while maintaining material workability.
Solution Approach 2:
The system applies periodic thermal action to the resin, alternating between cooling periods (to prevent curing and maintain workability) and heating periods (to enable deposition). This periodic temperature cycling manages the cure process to prevent progressive clogging while maintaining operational capability.
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 successful deposition of elongate fibers in desired orientations within the printed object, maintaining the feedstock line's integrity and preventing damage, while ensuring proper curing and adhesion during the manufacturing process.
Implementation Method 1
The rigidizing mechanism is configured to transform the resin of the feedstock line from the first at least partially uncured state to a rigid at least partially uncured state
Implementation Method 2
The de-rigidizing mechanism is configured to transform the resin of the feedstock line, as the feedstock line passes through the delivery guide or as the feedstock line exits the delivery guide, from the rigid at least partially uncured state to a second at least partially uncured state
Implementation Method 3
The curing mechanism is configured to transform the resin of the feedstock line, deposited by the delivery guide along the print path, from the second at least partially uncured state to an at least partially cured state
Data Source
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AI summary
A system (300) for additively manufacturing an object (102) comprises a source (302) of a feedstock line (106), a rigidizing mechanism (112) that receives the feedstock line (106) from the source (302) and transforms the resin (110) from a first at least partially uncured state to a rigid at least partially uncured state, a delivery guide (116) that deposits the feedstock line (106) along a print path (114), a feed mechanism (126) that feeds the feedstock line (106) through the delivery guide (116), a de-rigidizing mechanism (118) that transforms the resin (110) from the rigid at least partially uncured state to a second at least partially uncured state, and a curing mechanism (120) that transforms the resin (110) from the second at least partially uncured state to an at least partially cured state. (Fig. 2)