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Method for the design and manufacture of composites having tunable physical properties

  • US 10,558,199 B2
  • Filed: 11/09/2018
  • Issued: 02/11/2020
  • Est. Priority Date: 02/13/2018
  • Status: Active Grant
First Claim
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1. A method for the design and manufacture of a replica composite object based on an original object, the manufacture accomplished using additive manufacturing, the method comprising the steps of:

  • identifying one or more physical properties of an original object;

    determining one or more physical properties of a plurality of base materials;

    determining one or more physical properties of a plurality of bodies;

    comparing the identified physical properties of the original object with the physical properties of the plurality of base materials and the physical properties of the plurality of bodies, and selecting at least one of the plurality of base materials and at least one of the plurality of bodies;

    determining one or more desired anisotropic physical properties of the replica composite object based on the identified one or more physical properties of the original object, wherein the anisotropic physical properties exhibit orientation-dependent mechanical behavior;

    dividing at least one unit of the replica composite object into a plurality of subunits, each of the plurality of subunits in the at least one unit including an identical set of the selected at least one of the plurality of base materials and at least one of the plurality of bodies, wherein a characteristic of an additive manufacturing system determines the number of the subunits;

    measuring a virtual response of the replica composite object to a virtual stimulation, and comparing the measured virtual response to an observed physical response of the original object to a stimulation based on the virtual stimulation;

    determining whether the virtual response differs from the physical response by more than a tolerance value;

    based on a determination that the virtual response differs from the physical response by more than the tolerance value, optimizing the one or more desired anisotropic physical properties of the replica composite object by adjusting the selected at least one of the plurality of base materials and at least one of the plurality of bodies, the optimization step configured to be performed; and

    based on a determination that the virtual response differs from the physical response by less than or equal to the tolerance value, instructing the additive manufacturing system to generate the replica composite object.

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