Functional Fiber Melt Insertion for Secure SLS/FDM 3D Printing
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Solution Overview
Problem
Existing methods for embedding functional fibers in workpieces during additive manufacturing processes, such as selective laser sintering (SLS) and fused deposition modeling (FDM), face limitations in fiber density and integration, as they typically integrate fibers with the material deposition process, leading to restricted freedom and potential fiber detachment.
Innovation Solution
A method and device that separately optimize the process for functional fiber insertion by melting the workpiece surface and inserting fibers into the melt, using a distinct process from the primary additive manufacturing method, ensuring secure integration and freedom of movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If functional fibers are integrated with material deposition process, then fiber integration is achieved, but fiber density is restricted and fiber detachment occurs
Solution Approach 1:
The patent separates the fiber insertion process from the material deposition process into two distinct operations. The fiber insertion device places fibers on the workpiece surface first, then the material deposition process deposits material around them. This segmentation allows each process to be optimized independently, enabling higher fiber density without compromising integration security.
Solution Approach 2:
The patent applies preliminary action by inserting functional fibers onto the workpiece surface before completing the material deposition process. The fibers are positioned in advance, allowing the subsequent material deposition to securely embed them. This preliminary placement ensures fibers are properly positioned and densely packed before the enclosing material is applied.
2Ease of operation
If fibers are inserted into settled material coil, then fiber insertion is possible, but only one fiber can be introduced and density is limited
Solution Approach 1:
The patent extracts the fiber insertion operation from the material deposition process. Instead of trying to insert fibers during or after material deposition, the system uses a separate fiber insertion device that operates independently. This extraction allows multiple fibers to be inserted with precision before material is deposited, dramatically increasing fiber density while maintaining ease of operation.
Solution Approach 2:
The patent introduces an intermediary fiber insertion device that acts as a mediator between the fiber supply and the final composite structure. This intermediary device handles the complex task of precise fiber placement, allowing the main material deposition system to focus on its primary function. The intermediary enables high-density fiber insertion through specialized mechanisms not present in standard deposition systems.
3Reliability
If separate process is used for fiber insertion, then fiber density and integration are improved, but device complexity increases
Solution Approach 1:
The patent merges the fiber insertion device with the material deposition system into an integrated hybrid system. The fiber insertion device and material deposition device share common components such as the build platform, coordinate system, and control system. This merging reduces overall device complexity while maintaining the benefits of separate fiber insertion and material deposition processes.
Solution Approach 2:
The patent applies universality by designing the fiber insertion device to work with various fiber types and material deposition processes. The system can handle different fiber materials (carbon, glass, aramid) and is compatible with multiple deposition techniques. This multi-functionality reduces the need for specialized equipment for each fiber type, thereby reducing overall device complexity while maintaining high integration reliability.
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
This approach allows for higher fiber density and secure integration of functional fibers within the workpiece, preventing detachment during subsequent processes, enhancing the mechanical and functional properties of the composite material.
Implementation Method 1
said method comprising the steps of: locally melting powder or a surface of a workpiece (wst) with a laser beam (lb) to a melt (m)
Implementation Method 2
after the laser beam has moved on, the molten material solidifies and fixes the inserted functional fiber (ff) in place
Data Source
AI summary
A process embeds functional fibers in a workpiece during selective laser sintering. In a process variant, parts of a powder layer are sintered before the insertion process, for example using a laser beam. A heating device then subsequently re-melts the already melted workpiece parts. Through a channel in the heating device, the functional fiber is fed to the melt or melt-like mass by means of a feed device and inserted into the melt or melt-like mass at the insertion point. Due to the movement of the heating device, the completely or partially melted area moves away from the heating element and is heated less, causing it to cool and solidify comprising the already inserted functional fiber. This variant can also be used for inserting fibers into objects created, for example, by injection molding or extruder-based 3D printing or other additive manufacturing processes.