Additive Manufacturing Tool Paths for Continuous Fiber Placement
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Solution Overview
Problem
Existing additive manufacturing systems lack efficient methods for determining optimal tool paths to achieve precise control over the placement and orientation of continuous fibers within the manufactured structure.
Innovation Solution
A method and system for determining a tool path in additive manufacturing by receiving placement data for nodes with regional tool paths and operation data, and resolving these into a resolved tool path based on the received data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional FDM additive manufacturing is used, then the manufacturing process is simple and straightforward, but the structural strength and mechanical properties of the manufactured parts are limited
Solution Approach 1:
The patent embeds continuous fibers (such as carbon fiber, glass fiber, or aramid fiber) within the thermoplastic matrix material discharged from the print head. This composite material approach significantly enhances the structural strength, stiffness, and mechanical properties of the manufactured parts beyond what is achievable with thermoplastic alone, while maintaining the additive manufacturing process framework
Solution Approach 2:
The patent divides the manufacturing control into discrete nodes in the tool path, where each node contains specific operation data (such as fiber orientation angles, material deposition parameters, and curing settings). This segmentation allows for precise control of fiber placement and orientation at different locations, optimizing structural strength in critical areas without requiring complete system redesign
2Strength
If continuous fibers are embedded within the material, then the structural strength is multiplied beyond matrix-dependent strength, but the control over fiber placement and orientation becomes complex
Solution Approach 1:
The patent dynamically adjusts fiber orientation angles and placement parameters at each node based on the local structural requirements. The tool path resolution process continuously calculates optimal fiber angles and positions, allowing the system to adapt fiber placement to match stress distributions and load paths throughout the manufactured structure, thereby achieving precise fiber placement control
Solution Approach 2:
The patent varies multiple parameters including fiber orientation angles, fiber volume fraction, deposition speed, and temperature profiles at different nodes along the tool path. By changing these parameters locally rather than maintaining constant settings, the system achieves precise control over fiber placement and orientation to optimize structural strength in different regions of the manufactured part
3Manufacturing precision
If a resolved tool path is generated from multiple regional tool paths, then the control over material placement is improved, but the computational complexity and processing time increase
Solution Approach 1:
The patent divides the overall tool path into multiple regional tool paths, each associated with specific nodes containing operation data. This segmentation allows the system to process and resolve each region independently, managing computational complexity while maintaining precise control over material placement in each local area through node-specific parameters
Solution Approach 2:
The patent performs preliminary processing of regional tool paths by pre-calculating node data including fiber orientation angles, material deposition parameters, and operation settings before actual manufacturing. This preliminary resolution of nodes reduces real-time computational requirements during manufacturing, balancing processing time with material placement precision
Data Source
AI summary
Methods and associated systems and apparatus for determining a tool path for use in additively manufacturing a structure. The methods may include receiving placement data indicative of a relative placement of a plurality of nodes, each node including one or more regional tool paths and each regional tool path for additively manufacturing a region of the structure. The methods may also include receiving operation data indicative of an operation to be performed in relation to at least one of the plurality of nodes, and resolving the at least one of the plurality of nodes into a resolved tool path for use in additively manufacturing the structure based on the received placement data and operation data.