Vibrating Nozzle for Composite Additive Manufacturing
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Solution Overview
Problem
Existing manufacturing processes, such as extrusion and pultrusion, face challenges in achieving the required strength, form, and precision for composite structures due to issues like poor fiber-to-fiber adhesion, fiber impregnation, and bubble inclusion.
Innovation Solution
An additive manufacturing system with a vibrating nozzle that discharges a composite material comprising a matrix and continuous reinforcement, featuring a support for multi-dimensional movement, a vibration mechanism to generate oscillations, and a cure enhancer to enhance curing, along with a shoe and blade configuration to improve adhesion and impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If extrusion manufacturing is used to produce continuous structures, then productivity and manufacturing efficiency are improved, but the strength and structural integrity of the resulting structures deteriorate
Solution Approach 1:
The patent applies ultrasonic vibration to the nozzle during the extrusion process. This vibration creates oscillatory motion that enhances fiber impregnation into the matrix material, improves fiber-to-fiber adhesion, and eliminates bubble inclusions. The mechanical vibration transforms the standard extrusion process into a high-strength composite manufacturing process while maintaining continuous production capabilities.
2Strength
If pultrusion manufacturing is used to produce high-strength structures, then structural strength is improved, but manufacturing precision and form accuracy deteriorate
Solution Approach 1:
The ultrasonic vibration of the nozzle provides precise control over material discharge while enhancing fiber impregnation. This allows the system to achieve pultrusion-level strength through improved fiber-to-matrix bonding while maintaining the ability to create complex 3D geometries with high manufacturing precision that conventional pultrusion cannot achieve.
3Strength
If conventional pultrusion techniques are used, then structural strength is improved, but fiber-to-fiber adhesion and fiber impregnation deteriorate
Solution Approach 1:
The ultrasonic vibration generated by the vibrating nozzle creates high-frequency oscillations that mechanically work the composite material during discharge. This vibration enhances fiber impregnation by forcing fibers into the matrix material and improves fiber-to-fiber adhesion by creating intimate contact between adjacent fibers, directly addressing the reliability issues of conventional pultrusion.
4Productivity
If conventional extrusion manufacturing is used, then productivity is improved, but bubble inclusion and material defects deteriorate
Solution Approach 1:
The ultrasonic vibration of the nozzle creates cavitation and intense mixing effects in the composite material during discharge. This vibration disrupts bubble formation, forces trapped air and volatiles out of the material stream, and ensures complete impregnation of fibers with matrix material, thereby eliminating the harmful bubble inclusions that plague conventional extrusion processes.
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
The system enables the production of composite structures with enhanced strength and quality by improving fiber-to-fiber adhesion, fiber impregnation, and surface finish, addressing the limitations of traditional methods.
Implementation Method 1
a vibration mechanism configured to generate oscillations within the nozzle during discharge
Implementation Method 2
a cure enhancer configured to direct energy to the composite material during discharging to enhance curing of the matrix
Data Source
AI summary
A system is disclosed for use in additively manufacturing a composite structure. The system may include a nozzle configured to discharge a composite material, including a matrix and a continuous reinforcement. The system may also include a support configured to move the nozzle in multiple dimensions during discharge of the composite material, and a vibration mechanism configured to generate oscillations within the nozzle during discharge.