Robotic Multi-Extruder Module for 3D Composite Fiber Alignment
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Solution Overview
Problem
Current additive manufacturing technologies for composite materials are limited to 2.5D fabrication, lack fiber alignment with stress directions, require large and costly gantry machines, and are labor-intensive, failing to achieve high performance structural requirements.
Innovation Solution
A robotic 3D printing machine with a rotatable extruder module and dual nozzle assembly, capable of extruding multiple materials, including continuous fibers, to align fibers with stress directions and improve dexterity and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional gantry style additive manufacturing machines are used, then fabrication capability is provided, but machine size and cost increase significantly for large parts
Solution Approach 1:
The patent replaces the traditional gantry-style mechanical positioning system with a robotic end-effector approach. Instead of moving a large gantry structure across the entire build volume, a compact robotic arm with integrated extrusion capability performs the fabrication task, significantly reducing machine footprint while maintaining fabrication capability for large parts.
Solution Approach 2:
The patent segments the fabrication system into a mobile robotic end-effector and a stationary build platform. The end-effector contains the extrusion mechanism and positioning functions, allowing it to be repositioned throughout the build volume. This segmentation enables large part fabrication without requiring a proportionally large machine structure.
2Manufacturing precision
If traditional 2.5D additive manufacturing processes are used, then layer-by-layer fabrication is achieved, but true 3D fabrication with concurrent x, y, z building is not possible
Solution Approach 1:
The patent implements dynamic control of the robotic end-effector to enable true 3D fabrication. The end-effector can be positioned and oriented in any direction within the build volume, allowing concurrent material deposition in x, y, and z directions. This dynamic positioning capability transforms the static layer-by-layer process into a fully three-dimensional fabrication process.
Solution Approach 2:
The patent adds the z-dimension to the traditional 2.5D layer-by-layer approach by enabling the end-effector to deposit material in the vertical direction while maintaining x-y positioning capability. This dimensional enhancement allows concurrent building in all three spatial directions, achieving true 3D fabrication.
3Ease of manufacture
If known composite additive manufacturing approaches are used, then composite structures can be fabricated, but fiber alignment with stress directions is not achieved
Solution Approach 1:
The patent applies local quality control by enabling the end-effector to independently control fiber orientation at each deposition location. The robotic system can align fibers with the principal stress directions at specific points within the composite structure, creating locally optimized fiber alignment rather than uniform alignment throughout the entire part.
Solution Approach 2:
The patent uses dynamic control of the end-effector orientation to achieve proper fiber alignment. The system can adjust the extrusion angle and orientation at each step to match the local stress distribution in the composite structure, enabling precise fiber alignment with stress directions throughout the fabrication process.
4Productivity
If known additive manufacturing technologies are used, then 3D printing is achieved, but labor intensity and cost remain high due to skilled technician requirements
Solution Approach 1:
The patent implements self-service capabilities through automated robotic control of the end-effector. The robotic system can autonomously position and orient the extrusion mechanism without requiring skilled fabrication technicians. Programming the robotic end-effector with appropriate toolpaths and parameters enables unskilled or minimally skilled operators to perform composite fabrication tasks that traditionally required expert craftsmanship.
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 true 3D fabrication of high-performance composite structures with enhanced fiber alignment, reduced machine size and cost, and increased flexibility, overcoming limitations of traditional methods.
Implementation Method 1
a FFF process provides a stock material to a heated nozzle, where it is extruded therefrom to be laid down layer by layer to build up a desired product
Implementation Method 2
a FFF process provides a stock material to a heated nozzle, where it is extruded therefrom to be laid down layer by layer
Implementation Method 3
the molten polymer or fiber reinforced polymer material immediately begins to harden once it is extruded from the nozzle
Data Source
Figure 1
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AI summary
A printing machine for fabricating high performance 3D integrated composite structures, where the machine includes a robot (12) having a base portion (14), a robot arm and an end joint (22) secured to the arm opposite to the base portion (14), a plurality of sources of extrudable material, and an end-effector mounted to the end joint (22). The end-effector includes a multiple-extruder module having a first extruder and a second extruder each including a separate nozzle assembly, wherein the first extruder receives one extrudable material and the second extruder receives another extrudable material.