Method and apparatus for continuous composite three dimensional printing

• US 10,449,711 B2
• Filed: 06/01/2017
• Issued: 10/22/2019
• Est. Priority Date: 08/29/2012
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: Continuous Composites Inc.
• Inventors: Tyler, Kenneth Lyle
• Primary Examiner(s): Yi, Stella K
• Application Number:
  US15/610,960
• Publication Number:
  US 20170266877A1
• Time in Patent Office: 873 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 additively manufacturing a three-dimensional object, comprising:

an extruder configured to mix a first epoxy part with a second epoxy part to create an epoxy, and to discharge a continuous fiber that is at least partially coated in the epoxy;

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 fiber to be discharged from the extruder in a three-dimensional shape.

2. The apparatus of claim 1, wherein:

the first epoxy part is a resin; and

the second epoxy part is at least one of a catalyst and a hardener.

3. The apparatus of claim 1, further including a plurality of liquid hoses configured to dispense the first and second epoxy parts into the extruder.

4. The apparatus of claim 3, further including at least one reservoir from which the plurality of liquid hoses dispense the first and second epoxy parts.

5. The apparatus of claim 1, further including a mixing chamber configured to mix the first and second epoxy parts together.

6. The apparatus of claim 5, wherein the mixing chamber is configured to apply at least one of heat and pressure to the epoxy prior to discharge.

7. The apparatus of claim 1, further including:

a mixer; and

a variable connection allowing for connection of the mixer to the extruder.

8. The apparatus of claim 1, wherein the continuous fiber includes at least one of a carbon fiber, a glass fiber, an aramid fiber, a metallic wire, and a fiber optic.

9. The apparatus of claim 1, wherein the continuous fiber is coated with the epoxy while inside of the extruder.

10. The apparatus of claim 1, wherein the extruder is configured to introduce a gas to encourage hardening of the epoxy.

11. The apparatus of claim 1, further including a means for curing the epoxy after discharge from the extruder.

12. The apparatus of claim 11, wherein the means for curing the epoxy is a UV light.

13. The apparatus of claim 11, wherein the means for curing the epoxy is heat.

14. The apparatus of claim 1, further including a plurality of spools configured to introduce a plurality of different continuous fibers into the extruder.

15. The apparatus of claim 14, further including a loom configured to provide the plurality of different continuous fibers from the plurality of spools into the extruder sequentially.

16. An apparatus for additively manufacturing a three-dimensional object, comprising:

a mixing chamber configured to receive a resin and at least one of a catalyst and hardener;

a mixer configured to mix the resin and the at least one of the catalyst and the hardener to create an epoxy;

a nozzle configured to discharge a continuous strand material that is different from the epoxy and at least partially coated in the epoxy while inside of nozzle; and

an automated mechanical apparatus connected to the nozzle; and

at least one processing unit programmed to control the automated mechanical apparatus to move the nozzle so as to cause the continuous strand material to be discharged from the nozzle in a three-dimensional shape.

17. The apparatus of claim 16, further including a means for curing the epoxy after discharge from the nozzle.

18. A head for an additive manufacturing system, comprising:

a mixing chamber configured to receive a resin and at least one of a catalyst and a hardener;

a mixer configured to mix the resin and the at least one of the catalyst and the hardener to create an epoxy; and

a nozzle configured to discharge a continuous fiber at least partially coated in the epoxy while inside of the head.

19. The head of claim 18, wherein the mixer is at least one of static and disposable.

20. The head of claim 18, further including a means for curing the epoxy after discharge from the nozzle.