Segmented Mold Pattern Assembly With Hollow Thermoset Infusion

The patent replaces expensive carbon fiber with cheaper alternative fill materials such as wood fiber, glass fiber, or metal powder that can be mixed with thermoplastic materials. This substitution maintains adequate structural strength for many applications while significantly reducing material costs, making additive manufacturing economically viable for broader applications.

The patent uses composite materials consisting of thermoplastic base materials mixed with various fill materials (carbon fiber, wood fiber, glass fiber, metal powder) to achieve desired mechanical properties. By optimizing the composition and ratio of these composite materials, the patent balances structural strength requirements with cost reduction goals.

The patent modifies processing parameters including printing temperature, cooling rate, and layer thickness to control thermal shrinkage and warping. By optimizing these parameters, the patent maintains the ease of thermoplastic processing while minimizing dimensional inaccuracies and warping during the cooling phase.

The patent accounts for thermal expansion and contraction of thermoplastic materials during the printing and cooling process. By pre-compensating for expected shrinkage in the digital model and controlling cooling rates, the patent reduces warping and maintains manufacturing precision while preserving the benefits of thermoplastic ease of processing.

The patent optimizes the fill material content within specific ranges (e.g., 10-50% by weight) to balance structural properties with processability. By controlling the concentration of fill materials in the composite, the patent maintains adequate structural strength while ensuring the material remains processable through additive manufacturing systems without excessive viscosity or poor flow characteristics.

The patent develops composite material formulations with optimized compositions of base polymer and fill materials. By selecting appropriate base polymers and fill material combinations, the patent achieves a balance where high fill content provides structural benefits while the composite remains processable through standard additive manufacturing equipment.

The patent divides the additive manufacturing process into discrete layers that can be deposited using simpler, more cost-effective equipment. By segmenting the build process into layer-by-layer deposition, the patent achieves automation and precision benefits while using less expensive equipment compared to high-end 3D printing systems.

The patent uses digital models and computer-controlled fabrication to replicate complex geometries with high precision. By copying the digital design data into physical layers through controlled material deposition, the patent achieves automation and manufacturing precision while using more affordable equipment than traditional high-end 3D printers.