Profile Rod Additive Manufacturing for High-Deposition Fiber Composites
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Solution Overview
Problem
Current 3D printing technologies using fused filament fabrication face limitations such as small filament diameters, which restrict deposition rates, require complex methods for fiber-reinforced materials, and lead to issues like fiber breakage and nozzle clogging due to degradation of thermoplastic material.
Innovation Solution
An additive manufacturing device and method utilizing pre-tailored, pre-impregnated profile rods with larger diameters and adaptable cross-sections, which are fed into the printing system to improve deposition rates and reduce material degradation, allowing for continuous operation and easier nozzle cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If small diameter filaments (0.8mm-3mm) are used to enable winding and guiding, then the filament can be fed through the system, but the deposition rate is limited
Solution Approach 1:
The patent changes the diameter parameter of the filament from conventional small sizes (0.8mm-3mm) to large diameter profile rods (5mm-20mm). This parameter change enables significantly higher deposition rates while the profiled cross-section and heating system design ensure proper melting and feeding of the larger material
Solution Approach 2:
The patent segments the continuous filament into discrete profile rod segments that are fed individually into the heating system. Each profile rod is processed separately through melting and extrusion, eliminating the need for continuous winding and guiding of long filaments while maintaining high deposition rates
2Strength
If fiber-reinforced filaments are used, then material strength is improved, but cutting operations are required which interrupt continuous printing and may cause fiber breakage
Solution Approach 1:
The patent applies preliminary action by pre-impregnating the profile rods with fiber-reinforced material before printing. The fibers are already integrated into the profile rod structure, eliminating the need for cutting operations during printing and maintaining continuous operation while preserving fiber reinforcement benefits
Solution Approach 2:
The patent extracts the cutting operation from the printing process by using pre-cut profile rods as input material. The cutting function is performed beforehand on the profile rods outside the printing system, allowing the printing process itself to operate continuously without interruption or fiber breakage risks
3Productivity
If thick filaments are used to increase deposition rate, then material throughput is improved, but the filament requires longer heating time which increases degradation risk
Solution Approach 1:
The patent changes the heating parameters and heating zone design to accommodate thick profile rods. The heating system is optimized with increased heating power and extended heating zone length, reducing the heating time required for thick materials while maintaining control over degradation
Solution Approach 2:
The patent introduces dimensional changes by using profiled cross-sections (rectangular, triangular, etc.) instead of circular filaments. This dimensional change increases the surface area to volume ratio of the material, improving heat transfer efficiency and reducing heating time while maintaining large material throughput
4Productivity
If continuous filament is used, then material flow is maintained, but degraded material accumulates at the nozzle exit and cleaning becomes complicated
Solution Approach 1:
The patent segments the material feed into discrete profile rod units. Each profile rod is fed, melted, and extruded as a separate unit, creating natural interruption points in the material flow. This segmentation allows for easier cleaning of degraded material from the nozzle between segments, while maintaining continuous overall production
Solution Approach 2:
The patent implements periodic action by feeding profile rods in discrete intervals rather than continuous flow. Between each profile rod processing cycle, the nozzle can be cleaned or maintained, preventing accumulation of degraded material while maintaining high overall productivity through rapid cyclic operation
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 enhances deposition rates, reduces fiber breakage, and simplifies the printing process by using pre-cut, pre-impregnated profile rods, enabling the production of high-quality fiber-reinforced components with improved handling and material efficiency, suitable for industrial-scale applications like aircraft manufacturing.
Implementation Method 1
A heating element 112 so as to heat a thermoplastic material to the melting point thereof, or beyond
Implementation Method 2
heating duct 116 for the thermoplastic material... The heating element 112 heats a heating region 114
Implementation Method 3
a cooling installation 122. The cooling installation cools the thermoplastic material to below the melting point of the latter such that the thermoplastic material solidifies
Data Source
AI summary
A method of using solid profile rods instead of the usual filament coils for additive manufacturing methods such as 3D printing for industrial applications such as aircraft manufacturing, and to enable a more rapid production of fiber-composite components. The additive manufacturing device, or the 3D printer which generates the component layer by layer, respectively, comprises a material magazine in which a plurality of profile rods are stored. The profile rods are pre-tailored and are adapted to the component layer by layer. The profile rods, when printing, are successively retrieved from the material magazine and, by way of an infeed installation, guided to the nozzle of the additive manufacturing installation and subsequently applied to the printing bed so as to form the component layer by layer.