Method and apparatus for continuous composite three-dimensional printing
First Claim
Patent Images
1. A method of manufacturing a three-dimensional object, comprising:
- pre-impregnating a continuous strand material with a first polymer;
directing the pre-impregnated continuous strand material into an extruder nozzle;
directing a second polymer into the extruder;
heating the extruder;
coating the pre-impregnated continuous strand material with the second polymer;
discharging from the extruder a path of composite material containing the pre-impregnated continuous strand material and the second polymer; and
moving the extruder in multiple dimensions during discharging, such that the path extends from the extruder in multiple dimensions,wherein;
the first polymer is one of a thermoset and a thermoplastic; and
the second polymer is the other of the thermoset and the thermoplastic.
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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.
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Citations
23 Claims
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1. A method of manufacturing a three-dimensional object, comprising:
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pre-impregnating a continuous strand material with a first polymer; directing the pre-impregnated continuous strand material into an extruder nozzle; directing a second polymer into the extruder; heating the extruder; coating the pre-impregnated continuous strand material with the second polymer; discharging from the extruder a path of composite material containing the pre-impregnated continuous strand material and the second polymer; and moving the extruder in multiple dimensions during discharging, such that the path extends from the extruder in multiple dimensions, wherein; the first polymer is one of a thermoset and a thermoplastic; and the second polymer is the other of the thermoset and the thermoplastic. - View Dependent Claims (2, 3, 4, 5, 9)
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6. A method of manufacturing a three-dimensional object, comprising:
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pre-impregnating a continuous strand material with a first polymer; directing the pre-impregnated continuous strand material into an extruder; directing a second polymer into the extruder; heating the extruder; coating the pre-impregnated continuous strand material with the second polymer; discharging from the extruder a path of composite material containing the pre-impregnated continuous strand material and the second polymer; and partially curing the first polymer prior to coating the continuous strand material with the second polymer, wherein; the first polymer is one of a thermoset and a thermoplastic; and the second polymer is the other of the thermoset and the thermoplastic.
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7. A method of manufacturing a three-dimensional object, comprising:
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pre-impregnating a continuous strand material with a first polymer; directing the pre-impregnated continuous strand material into an extruder nozzle; directing a second polymer into the extruder; heating the extruder; coating the pre-impregnated continuous strand material with the second polymer; and discharging from the extruder a path of composite material containing the pre-impregnated continuous strand material and the second polymer, wherein; the first polymer is one of a thermoset and a thermoplastic; the second polymer is the other of the thermoset and the thermoplastic; and the continuous strand material includes at least one of fiber optics, metal wire, and rubber.
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8. A method of manufacturing a three-dimensional object, comprising:
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pre-impregnating a continuous strand material with a first polymer; directing the pre-impregnated continuous strand material into an extruder nozzle; directing a second polymer into the extruder; heating the extruder; coating the pre-impregnated continuous strand material with the second polymer; and discharging from the extruder a path of composite material containing the pre-impregnated continuous strand material and the second polymer, wherein; the first polymer is one of a thermoset and a thermoplastic; the second polymer is the other of the thermoset and the thermoplastic; and the continuous strand material includes carbon fibers.
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10. A method of manufacturing a three-dimensional object, comprising:
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pre-impregnating a continuous strand material with a first polymer; directing the pre-impregnated continuous strand material into an extruder nozzle; directing a second polymer into the extruder; heating the extruder; coating the pre-impregnated continuous strand material with the second polymer; discharging from the extruder a path of composite material containing the pre-impregnated continuous strand material and the second polymer; and moving the extruder during discharging, wherein; the first polymer is one of a thermoset and a thermoplastic; the second polymer is the other of the thermoset and the thermoplastic; and moving the extruder during discharging includes moving the extruder during discharging such that a path of composite material cures and hardens in space unsupported between a discharge start location and a discharge end location.
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11. A method of manufacturing a three-dimensional object, comprising:
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saturating a continuous strand material with a first polymer; partially curing the first polymer saturating the continuous strand material; directing the partially cured and saturated continuous strand material into an extruder; directing a second polymer into the extruder; coating the partially cured first polymer and continuous strand material with the second polymer; discharging from the extruder a path of composite material containing the continuous strand material, the first polymer, and the second polymer; moving the nozzle during discharging; and keeping at least one of the first and second polymers cool and away from light to prevent premature solidifying prior to discharging from the extruder. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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18. A method of manufacturing a three-dimensional object, comprising:
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saturating a continuous strand material with a first polymer; directing the saturated continuous strand material into an extruder coating the saturated continuous strand material with a second polymer inside of the extruder; discharging from the extruder a path of composite material containing the continuous strand material, the first polymer and the second polymer; moving the extruder during discharging; selectively interrupting the directing of continuous strand material into the extruder, such that only the first polymer and the second polymer discharge from the extruder during moving of the extruder. - View Dependent Claims (19, 20, 21, 22, 23)
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Specification