Method and apparatus for continuous composite three-dimensional printing

• US 10,315,355 B2
• Filed: 09/16/2016
• Issued: 06/11/2019
• Est. Priority Date: 08/29/2012
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: CC3D LLC
• Inventors: Tyler, Kenneth
• Primary Examiner(s): Yi, Stella K
• Application Number:
  US15/268,156
• Publication Number:
  US 20170050375A1
• Time in Patent Office: 998 Days
• CPC Class Codes: B29B 15/122 with a matrix in liquid form, e.g. as melt, solution or latex
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 70/06 Fibrous reinforcements only
• CPC Class Codes: B29C 70/384 Fiber placement heads, e.g. component parts, details or accessories
• CPC Class Codes: B29K 2105/0058 Liquid or visquous
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/10 Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing

Abstract

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

Claims

1. An apparatus for additive manufacturing of a three-dimensional object, comprising:

a supply of curable liquid material;

a supply of continuous strand material;

an extruder configured to discharge the continuous strand material at least partially coated in the curable liquid material;

a feeder configured to direct the continuous strand material to the extruder; and

a means at least one ultraviolet light for curing the curable liquid material attached to the extruder and aimed at a point of extrusion.

2. The apparatus of claim 1, wherein the continuous strand material is comprised of several strands in at least one of a tow, roving, and weave.

3. The apparatus of claim 1, wherein the continuous strand material is comprised of multiple materials, with at least one material encased within another.

4. The apparatus of claim 1, wherein the continuous strand material is hollow.

5. The apparatus of claim 1, further comprising at least two supplies of alternative continuous strand materials.

8. The apparatus of claim 1, further including:

an automated mechanical apparatus connected to the extruder; and

at least one processing unit programmed to control the automated mechanical apparatus to move the extruder so as to cause the continuous strand material to be pulled from the extruder.

9. The apparatus of claim 8, wherein the automated mechanical apparatus includes at least one of a robotic arm or a gantry system.

10. The apparatus of claim 8, also comprising an appendage attached to the extruder, wherein the at least one processing unit is further programmed to control the appendage to adjust portions of the curable liquid material and the continuous strand material after discharge from the extruder and before curing by the means for curing.

11. The apparatus of claim 10, wherein the at least one processor is programmed to:

control movement of the appendage to wrap uncured portions of the curable liquid material and the continuous strand material around a cured portion of the curable liquid material and the continuous strand material; and

thereafter control the means for curing the curable liquid material and the continuous strand material to cure the uncured portion.

12. The apparatus of claim 1, wherein the means for curing the curable liquid material has directional control to follow a path of the extruder.

13. The apparatus of claim 8, further including an anchor, wherein the at least one processing unit is further programmed to:

cause the extruder and the means for curing to adhere a path of the curable liquid material and the continuous strand material to the anchor; and

cause the automated mechanical apparatus to move the extruder away from the anchor such that the continuous strand material is pulled from the extruder.

14. The apparatus of claim 1, further including:

an anchor;

an automated mechanical apparatus connected to the extruder; and

at least one processing unit programmed to cause the automated mechanical apparatus to move the extruder relative to the anchor during discharge of the curable liquid material and the continuous strand material and to control the means for curing so as to cause a path of cured curable liquid material and the continuous strand material to extend away from the anchor into three-dimensional space without support at locations between the anchor and the extruder.

15. The apparatus of claim 14, wherein the at least one processing unit is further programmed to cause the automated mechanical apparatus to move the extruder and generate tension in the continuous strand material during discharge.

16. The apparatus of claim 1, further including a valve configured to allow the continuous strand material to pass from the feeder into the extruder and to inhibit the curable liquid material from entering the feeder.

6. An apparatus for additive manufacturing of a three-dimensional object, comprising:

a supply of curable liquid material;

a supply of continuous strand material;

an extruder configured to discharge the continuous strand material at least partially coated in the curable liquid material;

a feeder configured to direct the continuous strand material to the extruder;

a means for curing the curable liquid material attached to the extruder and aimed at a point of extrusion; and

a first means for cutting the continuous strand material and the curable liquid material from a tip of the extruder.

7. The apparatus of claim 6, further comprising a second means for cutting the continuous strand material at the feeder;

and at least one processing unit programmed to control the first and second means for cutting and the extruder such that a first path consisting of the curable liquid material and the continuous strand material and a second path consisting of only the curable liquid material are selectively discharged from the extruder.