Void-Free Composite Filament 3D Printing via Segmented Nozzle
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Solution Overview
Problem
Current three-dimensional printing techniques lack the ability to efficiently produce composite parts with the benefits of composite lay-up and filament winding, particularly in concave shapes and with reduced voids, leading to limitations in strength and durability.
Innovation Solution
A three-dimensional printing method using unmelted void-free fiber reinforced composite filaments, where the filament is heated and extruded through a conduit nozzle with a transverse pressure zone and ironing lip to maintain neutral to positive tension, ensuring bonding without buckling and voids, allowing for the creation of strong, durable composite parts in complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional FFF extrusion is used to print composite parts, then the manufacturing process is simple, but the parts contain voids and have reduced strength and durability
Solution Approach 1:
The printing process is divided into distinct zones: a clearance fit zone for feeding unmelted filament and a transverse pressure zone for heating and bonding. This segmentation allows each zone to be optimized independently - the clearance fit zone prevents buckling while the transverse pressure zone ensures void-free bonding, thereby improving part reliability without requiring complete process redesign
Solution Approach 2:
The filament is fed in an unmelted state through the clearance fit zone before entering the transverse pressure zone where heating and bonding occur. This preliminary positioning and tension maintenance prevents buckling and void formation before they can occur, ensuring high part strength and durability from the start of the printing process
2Adaptability or versatility
If conventional FFF extrusion is used, then the printing process is fast, but concave shapes cannot be formed due to filament buckling
Solution Approach 1:
The printing process is divided into distinct zones: a clearance fit zone for feeding unmelted filament and a transverse pressure zone for heating and bonding. This segmentation allows each zone to be optimized independently - the clearance fit zone prevents buckling while the transverse pressure zone ensures void-free bonding, thereby improving part reliability without requiring complete process redesign
Solution Approach 2:
The filament temperature is controlled to remain below melting point in the clearance fit zone (maintaining structural integrity for complex shapes) and then heated in the transverse pressure zone for bonding. This parameter change enables the formation of concave and complex shapes without buckling while maintaining printing efficiency
3Manufacturing precision
If the filament is heated to melt the matrix material, then bonding between layers is achieved, but the filament may buckle before reaching the bonding zone
Solution Approach 1:
The printing process is divided into distinct zones: a clearance fit zone for feeding unmelted filament and a transverse pressure zone for heating and bonding. This segmentation allows each zone to be optimized independently - the clearance fit zone prevents buckling while the transverse pressure zone ensures void-free bonding, thereby improving part reliability without requiring complete process redesign
Solution Approach 2:
The filament is fed in an unmelted state through the clearance fit zone before entering the transverse pressure zone where heating and bonding occur. This preliminary positioning and tension maintenance prevents buckling and void formation before they can occur, ensuring high part strength and durability from the start of the printing process
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 enables the production of parts with enhanced strength and reduced voids, capable of forming complex shapes, including concave designs, by maintaining filament tension and preventing buckling during the printing process.
Implementation Method 1
The filament is heated to a temperature greater than a melting temperature of the matrix material to melt the matrix material interstitially within the filament
Implementation Method 2
to melt the matrix material interstitially within the filament
Implementation Method 3
A ironing force is applied to the melted matrix material and the one or more axial fiber strands of the fiber reinforced composite filament with an ironing lip
Implementation Method 4
The unmelted composite filament is fed at a feed rate along a clearance fit zone that prevents buckling of the filament
Implementation Method 5
the ironing lip is translated adjacent to the part at a printing rate that maintains a neutral to positive tension in the fiber reinforced composite filament between the ironing lip and the part
Data Source
AI summary
According to one aspect, embodiments of the invention provide an additively manufactured part, comprising a top portion, a bottom portion, and a plurality of compacted composite filaments arranged in layers between the top portion and the bottom portion, each compacted composite filament including one or more axial fiber strands, wherein the plurality of compacted composite filaments includes a first compacted composite filament located in a first layer and a second compacted composite filament located in a second layer, the first layer being located closer to the bottom portion than the second layer, and wherein the second compacted composite filament layer is compressed against the first compacted composite filament, forming a vertically bonded rank in which the one or more axial fiber strands of the second compacted composite filament intrudes into the first compacted composite filament.