Reconfigurable Rod Tool for Curved Composite Parts
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Solution Overview
Problem
Current additive manufacturing (AM) techniques struggle to produce high-performance, unreinforced polymeric parts due to their poor mechanical properties, and existing methods for fiber-reinforced composite parts are limited by the difficulty of fiber incorporation and the planar nature of AM, which restricts the production of complex curved structures.
Innovation Solution
A reconfigurable tool is used with a stereolithographic printer to enable the manufacturing of curved glass fiber composite parts by forming a negative relief with transparent rods and locking them in place, allowing for the curing of fiber-resin composite materials without the need for expensive molds, thus overcoming the limitations of traditional AM methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional additive manufacturing methods are used, then manufacturing complexity is reduced, but the ability to produce curved composite structures is lost
Solution Approach 1:
The patent uses a physical mold to create a negative relief copy of the desired curved shape. This negative relief is then transferred to a flat substrate through a lamination process, enabling curved composite structures to be manufactured without requiring complex curved molds. The copying principle allows the complex shape to be captured once in a mold and replicated multiple times on flat substrates.
Solution Approach 2:
The patent transforms a three-dimensional curved surface into a two-dimensional negative relief pattern that can be applied to a flat substrate. By converting the curved geometry into a planar transferable pattern, the method enables curved composite manufacturing using standard flat substrate processing, effectively reducing the dimensional complexity required for mold fabrication.
2Manufacturing precision
If resin transfer molding methods are used, then complex 3D geometries with high fidelity are achieved, but manufacturing cost and complexity increase due to expensive tooling
Solution Approach 1:
Instead of requiring expensive custom molds for each complex geometry, the patent creates a reusable negative relief copy that can be applied to multiple substrates. This single mold can produce numerous high-fidelity complex 3D geometries by transferring the negative relief pattern to flat substrates, significantly reducing per-part tooling costs while maintaining manufacturing precision.
Solution Approach 2:
The negative relief mold created in this patent serves multiple functions: it can be applied to different flat substrates, reused for multiple production runs, and adapted to create various curved composite structures. This universal tool eliminates the need for dedicated expensive tooling for each specific part geometry, making high-precision complex 3D manufacturing more accessible.
3Quantity of substance
If automated fiber placement is used, then high-end parts with high volume fraction composites are produced, but hardware complexity and substrate requirements increase
Solution Approach 1:
The patent uses a negative relief copy to directly form the curved shape on the composite part. This simple copying mechanism replaces complex automated fiber placement hardware by using the mold's negative relief to guide fiber mat conforming and resin infusion, achieving high fiber volume fractions through a much simpler process and equipment setup.
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 method allows for the efficient and cost-effective production of high volume fraction fiber-reinforced parts with complex geometries, including curved structures, using standard stereolithographic printers, eliminating the need for molds and enabling rapid prototyping and replication of fiber-reinforced composite parts.
Implementation Method 1
a bundle of a plurality of light transmitting rods... allowing for the curing of fiber-resin composite materials
Data Source
AI summary
A reconfigurable tool suitable for use with a stereolithographic printer for composite manufacturing of a shaped object, comprising a bundle of a plurality of light transmitting rods each having a longitudinal axis, a diameter and first and second end surfaces, said rods being arranged in parallel, and each said rod being independently movable in an axial direction relative to other said rods when a shaping surface having a shape is pressed against the first end surfaces of the rods to thereby position the second end surfaces of the rods to form a negative relief of the shape of the shaping surface, and a releasable locking mechanism for maintaining the rods in the positions that forms the negative relief. Also, a method for printing a shaped object having a shape of a shaped surface using a stereolithographic printer in combination with the reconfigurable tool.