Fiber Composite Tool Paths With Variable Pitch and Orientation
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Solution Overview
Problem
Conventional tool path generation methods for additive manufacturing of anisotropic materials, such as continuous fiber printing and tailored fiber placement, are time-consuming, costly, and difficult to control, especially when aiming for a fiber layout that follows a given vector field with anisotropic topology optimization, as they require manual optimization to satisfy evenly pitched parallel space filling and orientation distribution conditions.
Innovation Solution
A method using a gradient-based algorithm to optimize a three-dimensional domain model for minimum deflection or stress, followed by solving Gray-Scott reaction diffusion equations to generate an anisotropic tool path with variable pitch, which is based on localized thickness and stress state, allowing for automated and customized tool path design for three-dimensional printing of fiber composite parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual optimization is used to satisfy evenly pitched parallel space filling and orientation distribution conditions, then fiber layout accuracy is improved, but time consumption and cost increase
Solution Approach 1:
The patent replaces manual mechanical optimization processes with automated computational algorithms. Specifically, it uses stream line tracing algorithms combined with vector field integration to automatically generate tool paths that satisfy both evenly pitched parallel space filling and orientation distribution conditions, eliminating the need for time-consuming manual design while maintaining fiber layout accuracy
Solution Approach 2:
The patent transforms the manual optimization problem into a parameter-driven computational process. By defining vector fields, pitch parameters, and boundary conditions as input parameters, the system automatically generates optimized tool paths through algorithmic computation, converting qualitative design requirements into quantifiable parameter optimization
2Extent of automation
If conventional stream line tracing algorithms are used, then automation is improved, but control over distance between paths deteriorates
Solution Approach 1:
The patent implements feedback control in the tool path generation process by continuously monitoring and adjusting the distance between consecutive tool paths. The system uses the defined pitch parameter to control spacing, and the vector field orientation to guide path generation, ensuring that automated generation maintains precise control over path distances while following the desired fiber orientation distribution
Solution Approach 2:
The patent introduces dynamic adaptability to the automated tool path generation by allowing the pitch and orientation parameters to vary according to the vector field distribution. The system dynamically adjusts path spacing and orientation based on local requirements while maintaining overall automation, enabling flexible control over path distances in response to changing design conditions
Data Source
AI summary
Methods are provided for designing and generating a tool path for three-dimensional printing of a fiber composite part. The method includes defining a three-dimensional domain model and determining a set of boundary conditions for the three-dimensional domain model. The methods include applying a gradient-based algorithm to a predetermined stress state located within the three-dimensional domain model in order to: (1) optimize the three-dimensional domain model for minimum deflection or stress using a structural mechanics algorithm for a composite article, and (2) provide a topologically optimized fiber composite part design and fiber orientation field. The methods include using the topologically optimized fiber composite part design and fiber orientation field as an input to solve Gray-Scott reaction diffusion equations to generate an anisotropic tool path for three-dimensional printing of the fiber composite part.