3D Print Head Compaction Control for Void-Free Fiber Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing continuous fiber 3D printing technologies face issues such as voids in structures due to crossing filaments, increased weight from metal pins, and the need for post-heating, which limits structure size and cost.
Innovation Solution
A system with a print head that includes modules for discharging and compacting material, controlled by a controller to adjust compaction force based on material characteristics, allowing for continuous fiber reinforcement and immediate curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crossing filaments are used to form ribs, then the structure can be formed, but voids are created within the ribs that lower performance
Solution Approach 1:
The patent applies dynamics by making the compaction force adjustable and variable during the manufacturing process. The compactor's force is not static but can be dynamically modified based on real-time material characteristics detected by the controller, allowing optimization of compaction to eliminate voids while maintaining structural integrity.
Solution Approach 2:
The patent changes physical parameters by selectively adjusting the compaction force parameter based on as-discharged material characteristics. The controller modifies the compaction parameter in response to varying material properties, ensuring optimal densification to prevent void formation without compromising the structural performance.
2Ease of manufacture
If metal pins are used to form isogrid structures, then the structure can be created, but the weight of the structure increases unnecessarily
Solution Approach 1:
The patent extracts and removes the metal pins from the manufacturing process entirely. Instead of using physical metal pins to form isogrid structures, the system uses a compactor to directly shape the discharged material into the desired geometry, eliminating the need for separate pin components and reducing overall structure weight.
Solution Approach 2:
The patent substitutes the mechanical pin-based system with a compaction-based system. The compactor replaces the function of metal pins by directly forming the rib structures through controlled material compaction, eliminating the need for separate fastening components.
3Reliability
If the structure is heated after formation, then the matrix can be cured, but the size of the structure is limited and cost increases
Solution Approach 1:
The patent applies preliminary action by performing compaction during the material discharge process itself, before the material fully sets. The compactor acts on the material while it is still pliable and being deposited, allowing real-time adjustment of material characteristics without requiring subsequent heating or post-processing steps.
Solution Approach 2:
The patent substitutes thermal curing with mechanical compaction. Instead of using heat to cure the matrix after structure formation, the system uses mechanical compaction forces during discharge to achieve the desired material properties and structural integrity, eliminating the need for post-formation heating equipment and expanding structure size capabilities.
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 system enables the production of strong, lightweight structures with complex geometries without voids and reduced heating requirements, enhancing structural performance and cost-effectiveness.
Implementation Method 1
a second module configured to compact the material as it discharges from the first module
Implementation Method 2
The controller may be configured to determine an as-discharged characteristic of the material, and to selectively adjust a force of the second module based on the as-discharged characteristic
Data Source
AI summary
A system is disclosed for additively manufacturing a structure. The system may have a support, and a print head operatively connected to and moveable by the support. The print head may include a first module configured to discharge a material, a second module configured to compact the material as it discharges from the first module, and a controller in communication with the second module. The controller may be configured to determine an as-discharged characteristic of the material, and to selectively adjust a force of the second module based on the as-discharged characteristic.