5-Axis Nozzle for Composite Filament Deposition
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Solution Overview
Problem
Current additive manufacturing technologies lack the ability to engineer internal mechanical characteristics of deposited materials in three dimensions and face challenges when generating layers over voids or unsupported areas, limiting design complexity and structural integrity.
Innovation Solution
A 5-axis additive manufacturing method using a nozzle that moves in three dimensions and rotates, allowing for the deposition of reinforced or consolidated printer filaments with aligned short reinforcements, enabling the creation of complex structures with enhanced mechanical properties by varying fiber orientations and matrix distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional additive manufacturing processes are used, then material deposition is possible, but internal mechanical characteristics cannot be engineered in three dimensions
Solution Approach 1:
The patent employs composite filaments containing short fiber reinforcements (e.g., carbon fiber, glass fiber) embedded in a polymer matrix. This composite material approach enables the deposited material to possess enhanced and engineerable internal mechanical characteristics in three dimensions, resolving the limitation of traditional AM processes that could only deposit homogeneous materials
Solution Approach 2:
The invention combines multiple capabilities into a single additive manufacturing system: 5-axis movement capability, composite material deposition, and variable fiber orientation control. This merging of functions allows simultaneous achievement of complex geometry fabrication and internal mechanical property engineering without requiring multiple separate processes
2Adaptability or versatility
If complex geometries are created, then design flexibility is improved, but layer support and structural integrity become problematic
Solution Approach 1:
The patent transitions from traditional 3-axis additive manufacturing to 5-axis additive manufacturing, adding two rotational dimensions. This enables the nozzle to approach the build plate from multiple angles and deposit material on complex, overhanging, and self-supporting geometries without requiring traditional support structures, thereby maintaining structural integrity while achieving design flexibility
Solution Approach 2:
The system enables local control of fiber orientation and material properties at different locations within the deposited structure. By varying fiber alignment and composite material composition locally, the structure achieves optimized mechanical properties and self-supporting characteristics in specific regions, ensuring overall structural integrity for complex geometries
3Strength
If fiber alignment is optimized, then mechanical strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent implements dynamic control of fiber orientation during the deposition process. The system can adjust fiber alignment in real-time based on the current deposition location, load requirements, and geometric features. This dynamic adaptation achieves optimized mechanical strength without requiring pre-planned static fiber patterns, managing manufacturing complexity through adaptive control
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 enables the production of parts with improved mechanical properties, such as strength and toughness, by aligning fibers and optimizing material distribution, allowing for the creation of complex geometries that were previously unprintable, thereby overcoming limitations in layer support and internal structure engineering.
Implementation Method 1
the nozzle can move in multiple directions and is not fixed to a specific axis. The material, which can be deposited from any angle using 5 axis machines, is melted upon deposition with a laser or electron beam.
Implementation Method 2
The material, which can be deposited from any angle using 5 axis machines, is melted upon deposition with a laser or electron beam.
Implementation Method 3
The material, which can be deposited from any angle using 5 axis machines, is melted upon deposition with a laser or electron beam.
Implementation Method 4
Stereolithography is an additive manufacturing process that works by focusing an ultraviolet (UV) laser on to a vat of photopolymer resin. Because photopolymers are photosensitive under ultraviolet light, the resin is solidified and forms a single layer of the desired three-dimensional object.
Data Source
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AI summary
An additive manufacturing apparatus having a three-dimensional movement system comprising a first part; a second part coupled to the first part and movable relative to the first part; a third part coupled to the first part and the second part and movable relative to the first part and movable relative to the second part wherein the three-dimensional movement system moves an assembly in three dimensions relative to a base; a rotatable build table coupled to the base, and rotatable in a first plane parallel to the base; and a nozzle, wherein the assembly comprises the nozzle, wherein the nozzle is rotatable in a second plane not parallel to the base, wherein the nozzle comprises an opening for passing a printer filament through the nozzle, and for depositing the printer filament onto the build plate.