In-Situ Curing Oven for Deep-Cure Composite 3D Printing
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Solution Overview
Problem
Some composite materials used in continuous fiber 3D printing require more intense cure energy and a specific cure environment that the head-mounted cure enhancer cannot provide, limiting the strength and quality of the structures produced.
Innovation Solution
An additive manufacturing system that includes a head to discharge continuous reinforcement coated with a matrix, a housing to enclose and move the reinforcement, and a controller to selectively activate infrared lamps and UV lights to create a controlled curing environment within an oven, ensuring thorough curing and sintering of the composite structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If only a head-mounted cure enhancer is used, then the device complexity is reduced, but the curing intensity and depth are insufficient for some composite materials
Solution Approach 1:
The curing system is divided into two independent parts: a head-mounted UV cure enhancer for initial surface curing and a separate infrared oven for deep internal curing. This segmentation allows each component to be optimized for its specific function without increasing overall system complexity excessively.
Solution Approach 2:
The infrared oven acts as an intermediary environment that provides controlled thermal conditions for deep curing of the matrix material. The oven mediates between the head-mounted UV enhancer and the composite material, enabling two-stage curing that achieves both surface and deep curing effectiveness.
2Strength
If a head-mounted cure enhancer is used, then the device complexity is reduced, but the curing depth is insufficient for thick or complex structures
Solution Approach 1:
The curing process is segmented into two stages: initial UV curing at the surface and subsequent infrared thermal curing for deep penetration. This allows the system to achieve adequate curing depth in structures that would be inaccessible to UV light alone.
Solution Approach 2:
The system changes the curing parameters by transitioning from UV radiation (head-mounted) to infrared thermal energy (oven environment). This parameter change enables deep curing of thick sections and complex geometries that cannot be reached by surface-level UV enhancement alone.
3Productivity
If a head-mounted cure enhancer is used, then the system is simpler to operate, but the curing speed is insufficient for production requirements
Solution Approach 1:
The curing operations are segmented into rapid initial UV curing followed by accelerated infrared thermal curing. This segmentation enables different parts of the material to cure simultaneously at optimal rates, increasing overall production speed.
Solution Approach 2:
The system maintains continuous useful action by immediately transitioning from UV curing to infrared oven curing without interruption. This continuous two-stage process eliminates idle time and maximizes curing speed for production requirements.
4Manufacturing precision
If a head-mounted cure enhancer is used, then the ease of operation is improved, but the manufacturing precision of curing is insufficient for high-quality composite structures
Solution Approach 1:
The curing process is segmented into two precisely controlled stages: UV curing for surface precision and infrared thermal curing for internal precision. This segmentation allows each stage to be optimized for its specific precision requirements.
Solution Approach 2:
The system incorporates feedback control through the controller that monitors and adjusts both the head-mounted UV enhancer and the infrared oven parameters. This feedback mechanism ensures precise control over curing conditions to achieve high manufacturing precision for quality composite structures.
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 system enhances the curing process, allowing for the production of stronger composite structures with improved curing depth, speed, and accuracy, and the ability to work with a wider range of materials, including high-temperature metals.
Implementation Method 1
a UV light located between the head and the housing
Implementation Method 2
an infrared lamp disposed at least partially inside the oven
Data Source
AI summary
A system is disclosed for additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement that is at least partially coated with a matrix, and a housing trailing from the head and configured to at least partially enclose the continuous reinforcement after discharge. The system may also include a heat source disposed at least partially inside the oven, and a support configured to move the head during discharging.