Composite Part Fabrication via Interlocking Layer Deposition
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Solution Overview
Problem
Current 3D printing technologies, such as FDM, face challenges in creating complex shapes and preventing delamination between layers due to the limitations of traditional nozzle orientations and material deposition methods.
Innovation Solution
A method involving the separate delivery and embedding of matrix and fiber materials using heated nozzles and rollers to create interlocking layers with enhanced bonding and structural integrity, allowing for non-planar layer deposition and improved resistance to delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional nozzle orientation and material deposition methods are used, then the printing process is simple, but complex shapes cannot be created and delamination occurs between layers
Solution Approach 1:
The nozzle system is made dynamically adjustable in orientation and position, allowing it to adapt to complex geometries during the printing process. This enables the creation of complex shapes while maintaining controlled material deposition at each layer interface to prevent delamination.
Solution Approach 2:
The invention extends the traditional three-axis printing system by adding rotational degrees of freedom to the nozzle, enabling four-dimensional control (x, y, z, and orientation). This additional dimensional control allows the nozzle to access and deposit material on complex, non-planar surfaces that would be impossible with fixed orientation.
2Strength
If matrix and fiber materials are delivered separately, then structural integrity is improved, but the delivery system becomes more complex
Solution Approach 1:
The invention combines multiple material delivery functions into an integrated system where matrix and fiber materials are delivered through coordinated but unified mechanisms. The separate delivery of materials is achieved through a single multi-functional deposition head that manages both material streams, reducing overall system complexity while maintaining the structural benefits of composite materials.
Solution Approach 2:
The invention utilizes composite material technology by delivering and embedding fiber reinforcement within a matrix material. This creates layered composite structures with enhanced structural integrity, where the fiber provides tensile strength and the matrix provides structural continuity and load distribution.
3Strength
If heated nozzles and rollers are used for material embedding, then bonding strength is enhanced, but energy consumption increases
Solution Approach 1:
The heated roller applies heat and pressure to the freshly deposited layer while it is still warm from the nozzle, creating an immediate bonding interface. This preliminary thermal action ensures strong interlayer bonding before the material fully cools, reducing the need for additional heating cycles and minimizing overall energy consumption.
Solution Approach 2:
The invention utilizes the phase transition of the thermoplastic matrix material from solid to molten state during deposition, and then back to solid during cooling and bonding. The heated roller accelerates this phase transition process at the layer interface, ensuring proper bonding while minimizing total thermal energy input by leveraging the material's inherent phase change properties.
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
The solution enables the fabrication of complex shapes with improved structural integrity and resistance to delamination, allowing for the creation of composite materials with enhanced strength and recyclability.
Implementation Method 1
The delivering can include melting the matrix material and embedding the fiber material within the matrix material
Implementation Method 2
re-melting previously delivered matrix material using the heated roller, and pressing the fiber material into the re-melted matrix material using the heated roller
Implementation Method 3
pressing the fiber material into the re-melted matrix material using the heated roller
Implementation Method 4
compacting and bonding the first and second layers of matrix material and the layer of fiber material together using an iron tool
Data Source
AI summary
A controller of an additive manufacturing system including an extruder nozzle is programmed to: cause the extruder nozzle to deposit one or more first material segments with at least one first locking portion having a first shape; and cause the extruder nozzle to deposit one or more second material segments with at least one second locking portion having a second shape; wherein the second shape of the at least one second locking portion engages with the first shape of the at least one first locking portion, whereby the at least one second locking portion forms an interlock with the at least one first locking portion.