Method and apparatus for continuous composite three-dimensional printing

• US 10,603,836 B2
• Filed: 11/04/2016
• Issued: 03/31/2020
• 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:
  US15/344,235
• Publication Number:
  US 20170080642A1
• Time in Patent Office: 1,243 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. 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.

2. The method of claim 1, further including keeping the first polymer cool and away from light to prevent premature curing prior to discharging from the extruder.

3. The method of claim 1, further including pressurizing the extruder.

4. The method of claim 1, further including directing a filler material to mix with at least one of the thermoplastic and the thermoset.

5. The method of claim 4, wherein the filler material includes flakes of fiber.

9. The method of claim 1, further including selectively interrupting the directing of continuous strand material into the extruder, such that only the thermoplastic and the thermoset discharge from the extruder.

6. 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;

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.

7. 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; 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.

8. 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; 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.

10. 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 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.

11. A method of manufacturing a three-dimensional object, comprising:

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.

12. The method of claim 11, further including pressurizing the extruder.

13. The method of claim 11, further including directing a filler material to mix with at least one of the thermoplastic and the thermoset.

14. The method of claim 13, wherein the filler material includes flakes of fiber.

15. The method of claim 11, wherein the continuous strand material includes at least one of fiber optics, metal wire, and rubber.

16. The method of claim 11, wherein the continuous strand material includes carbon fibers.

17. The method of claim 11, wherein moving the extruder during discharging includes moving the nozzle 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.

18. A method of manufacturing a three-dimensional object, comprising:

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.

19. The method of claim 18, further including directing a filler material to mix with at least one of the first polymer and the second polymer.

20. The method of claim 19, wherein the filler material includes flakes of fiber.

21. The method of claim 18, wherein the continuous strand material includes at least one of fiber optics, metal wire, rubber, and carbon fibers.

22. The method of claim 18, wherein the continuous strand material includes carbon fibers.

23. The method of claim 18, wherein 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.