Additive Manufacturing With Radiant Curing for Multi-Material Composites
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Solution Overview
Problem
Existing additive manufacturing technologies face limitations in forming multi-material components with varying densities and material combinations, particularly in creating composite structures with short fiber reinforcements and diverse particle sizes.
Innovation Solution
An additive manufacturing apparatus that utilizes a stage and radiant energy device to layer resin and constituent materials, such as short fibers, to form composite components with varied densities and material compositions, employing mechanisms like pneumatic actuation and precise energy projection to cure the materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional additive manufacturing processes are used, then single-material components can be produced, but multi-material components with varying densities and fiber reinforcements cannot be formed
Solution Approach 1:
The patent divides the material deposition system into separate hoppers for different materials (resin, short fibers, particles) with independent control mechanisms. Each material can be deposited selectively onto the support in specific patterns, enabling multi-material component formation while maintaining manageable system complexity through modular architecture
Solution Approach 2:
The radiant energy device and support structure serve multiple functions: they cure different material types (resin, fibers, particles), support various deposition patterns, and enable formation of diverse component structures. This multi-functionality increases adaptability without proportionally increasing device complexity
2Strength
If high fiber loading is used to enhance mechanical properties, then structural integrity improves, but material deposition and curing complexity increases
Solution Approach 1:
The system enables different fiber concentrations, orientations, and types to be deposited in different regions of the component based on local structural requirements. High fiber loading can be applied specifically where enhanced mechanical properties are needed, while other regions use lower concentrations, optimizing both strength and processability
Solution Approach 2:
The patent combines multiple materials (resin matrix, short fibers, and particles) in controlled ratios and distributions to create composite structures. The resin provides binding and flexibility, fibers provide tensile strength, and particles can fill voids or provide specific functional properties, achieving high mechanical performance through synergistic material combinations
3Adaptability or versatility
If multi-material deposition is implemented to create varied density components, then component versatility improves, but manufacturing precision requirements increase
Solution Approach 1:
The system pre-mixes certain material combinations (such as resin with particles or resin with short fibers) in controlled ratios before deposition. This preliminary preparation ensures consistent material properties and reduces the precision requirements during the actual deposition process, as the pre-mixed materials are more uniform and easier to place accurately
Solution Approach 2:
The resin acts as an intermediary material that binds other constituents (fibers, particles) together and provides a workable matrix during deposition. The resin's流动性 allows for easier material placement and leveling, compensating for minor positioning variations and reducing the overall manufacturing precision requirements while still achieving the desired varied density 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
Enables the production of multi-material and multi-particle size parts with enhanced mechanical properties, allowing for the creation of composite components with greater than 10% fiber loading and varied densities, improving structural integrity and versatility.
Implementation Method 1
radiant energy is produced from a radiant energy device and directed through a window to cure the resin to a component that is supported by a stage in the build zone
Data Source
AI summary
An additive manufacturing apparatus includes a support configured to support a resin and a constituent material. A support plate includes a window. A stage is configured to hold one or more composite layers of the resin and the constituent material to form a composite component positioned opposite the support plate. A radiant energy device is positioned on an opposite side of the support from the stage and is operable to generate and project radiant energy in a patterned image through the window. An actuator assembly is configured to move the stage in a Z-axis direction and a Y-axis direction.