Tow Placement Head With Extrusion Switching for Precise Fiber Steering
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Solution Overview
Problem
Existing composite manufacturing processes are labor-intensive, require skilled labor, sophisticated apparatus, and molds, leading to high costs and limited complexity in part fabrication, with issues like fiber steering limitations, prepreg storage requirements, and extensive post-processing.
Innovation Solution
A tow placement process using a computer-controlled fiber placement head for steered deposition of continuous fibers, combined with a numeric controlled additive process that includes toolpath generation, extrusion modes, and a modular print head with heating and cutting mechanisms to ensure precise layer adhesion and eliminate velocity mismatches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated fiber placement systems are used to apply composite material to highly contoured surfaces, then manufacturing precision is improved, but device complexity increases due to sophisticated apparatus requirements
Solution Approach 1:
The automated fiber placement system is segmented into modular components: a robotic arm for positioning, a heating element for matrix material treatment, and a fiber feed mechanism. This segmentation allows each component to perform its function independently, reducing overall system complexity while maintaining placement precision through coordinated operation of simpler individual modules.
Solution Approach 2:
The patent replaces complex mechanical fiber steering mechanisms with a computational approach. A computer controls the robotic arm's movement along predetermined paths and adjusts the heating element's operation, substituting mechanical complexity with software-based path planning and control algorithms to achieve precise fiber placement on contoured surfaces.
2Manufacturing precision
If molds are used in composite manufacturing processes, then manufacturing precision is improved, but loss of time increases due to additional lead times
Solution Approach 1:
The invention extracts and eliminates the mold component from the composite manufacturing process. Instead of using traditional molds to define part geometry, the system directly deposits fiber reinforcement and matrix material in the desired configuration using a computer-controlled robotic arm, achieving precise part geometry without the time-consuming mold fabrication and removal steps.
Solution Approach 2:
The system performs preliminary digital modeling and path planning before physical manufacturing. Computer-generated three-dimensional models and predetermined deposition paths allow the system to prepare the manufacturing sequence in advance, enabling direct fabrication without molds and significantly reducing lead time while maintaining geometric precision through digital guidance.
3Strength
If fiber steering is implemented in composite manufacturing, then strength is improved, but device complexity increases due to sophisticated steering apparatus
Solution Approach 1:
The patent replaces complex mechanical fiber steering apparatus with a computer-controlled robotic positioning system. The computer calculates optimal fiber paths to achieve desired strength characteristics and guides the robotic arm to deposit fibers accordingly, substituting mechanical steering complexity with computational path optimization while maintaining enhanced composite strength through controlled fiber orientation.
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 fabrication of complex composite parts at reduced costs without molds, reducing labor intensity and post-processing, while ensuring high strength and precision through precise fiber steering and adhesion.
Implementation Method 1
The nozzle is provided with a heating element towards the end facilitating in the melting and smooth flow of the material exiting from nozzle outlet
Implementation Method 2
ensuring greater adhesion with underlying layers
Data Source
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AI summary
The present disclosure describes a tow placement process with an extrusion mode switching. The method includes heating a roving of the desired continuous fiber material pre-impregnated with a desired matrix material; depositing said continuous fibers on a deposition surface to be steered in desired directions using a fiber placement head controlled by a computer; and said streak of fibers being steered and deposited upon each other on a layer by layer basis.