Hybrid additive manufacturing method

• US 10,336,056 B2
• Filed: 08/31/2016
• Issued: 07/02/2019
• Est. Priority Date: 08/31/2015
• Status: Active Grant

• Current Assignee: Colorado School of Mines
• Original Assignee: Colorado School of Mines
• Inventors: Hemphill, Ryan L., Young, Kevyn C., Harris, Maxwell T., Short, Adam R., Van Bossuyt, Douglas L.
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US15/253,541
• Publication Number:
  US 20170057164A1
• Time in Patent Office: 1,035 Days
• Field of Search: 264112, 264236, 264255, 264308, 264401, 264494, 264496
• 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 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/295 Heating elements
• 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 80/00 Products made by additive manufacturing

Abstract

A hybrid additive manufacturing method that allows for precise deposition of various photo curable resins without the use of a vat has been developed. This method utilizes thermoplastics for an exterior shell and structural support. This method of resin or epoxy deposition allows for stronger parts to be printed more rapidly through hybridization of two additive manufacturing methods. This hybrid nature greatly expands material compatibilities from strictly thermoplastics to thermoplastics and any photo curable resins. Furthermore, reinforcing materials or dopants can be incorporated into the part using the method and apparatus.

Claims

1. A method to produce a thermoplastic and filled material part, comprising:

producing a shell, wherein the shell comprises at least one layer of a thermoplastic material and wherein the shell is produced by fused filament fabrication;

providing at least one layer of a filler material to the shell, wherein the filler material is a photo-curing resin, an epoxy and combinations thereof, and wherein the filler material is provided to the shell manually by a user; and

curing the filler material to produce a thermoplastic and filled material part.

2. The method of claim 1, wherein the at least one layer of the filler material comprises between about 1 and about 100,000 layers.

3. The method of claim 1, further comprising producing an infill structure, wherein the infill structure is produced by fused filament fabrication.

4. The method of claim 1, further comprising providing at least one reinforcing material to the at least one layer of the filler material before the at least one layer of the filler material is cured.

5. The method of claim 4, wherein the at least one reinforcing material is a carbon particle, a fiberglass, a metal fiber, a metal particle, a poly(imino-1,4-phenyleneiminocarbonyl-1,4-phenylenecarbonyl), a carbon fiber, a pliable fiber, a nylon material, and a polymer material.

6. The method of claim 4, wherein the at least one reinforcing material is orientated in the same direction.

7. The method of claim 4, wherein the at least one reinforcing material is a global fiber, a short fiber or a long fiber.

8. The method of claim 4, wherein the at least one reinforcing material is randomly oriented.

9. The method of claim 1, wherein the thermoplastic material is selected from the group consisting of a polylactic acid, an acrylonitrile butadiene styrene, a high impact polystyrene, a nylon material, and combinations thereof.

10. The method of claim 1, wherein the filler material is the photo-curing resin and wherein the photo-curing resin comprises an acrylate ester.

11. The method of claim 1, wherein the filler material is the epoxy, and wherein the epoxy is a quick cure epoxy, a two-part epoxy or combinations thereof.

12. The method of claim 1, wherein the fused filament fabrication is automated.

13. The method of claim 1, wherein the filler material is the photo-curing resin, and wherein the curing step comprises exposing the filler material to a light source.

14. The method of claim 13, wherein the light source is an ultraviolet light.

15. The method of claim 1, further comprising:

treating at least one surface of the shell prior to providing the at least one layer of the filler material to the shell by a method selected from the group consisting of a chemically etching process, or a roughening of a surface of the shell; and

cleaning the at least one surface with a polar solvent, a non-polar solvent, or a combination thereof.

16. The method of claim 13, wherein the light source is a laser or a flood light.

17. The method of claim 1, wherein a layer of the at least one layers of the filler material is provided to the shell and cured before a second layer of the at least one layers is provided to the shell.

18. The method of claim 1, further comprising removing air bubbles in the filler material prior to the curing.

19. The method of claim 3, wherein the thermoplastic and filled material part comprises between 10 vol. % and 50 vol. % of the infill.

20. The method of claim 1, wherein the filler further comprises a dopant material comprising at least one of a metal, an iron, a silver, a copper, a ceramic, an alumina, an organic material, a carbon material, a carbon containing material, a graphene, and a carbon black material.