Multilayer fiber reinforcement design for 3D printing

• US 10,603,841 B2
• Filed: 06/26/2017
• Issued: 03/31/2020
• Est. Priority Date: 03/22/2013
• Status: Active Grant

• Current Assignee: MarkForged, Inc
• Original Assignee: MarkForged, Inc
• Inventors: Mark, Gregory Thomas, Woodruff, Rick Bryan, Benhaim, David Steven, Parangi, Abraham Lawrence, Sklaroff, Benjamin Tsu
• Primary Examiner(s): Zhao, Xiao S
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US15/633,182
• Publication Number:
  US 20170334136A1
• Time in Patent Office: 1,009 Days
• 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 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/227 Driving means
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 70/16 using fibres of substantial or continuous length non-woven fabrics per se D04H3/00
• CPC Class Codes: B29K 2025/08 Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene B29K2055/02 takes precedence
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/085 Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
• CPC Class Codes: B29L 2009/00 Layered products
• 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

Abstract

According to at least one aspect, embodiments of the invention provide a 3D printer comprising an anisotropic head that solidifies, along anisotropic toolpaths, fiber swaths having an anisotropic characteristic oriented relative to a trajectory of the anisotropic tool paths, an isotropic head that solidifies, along isotropic toolpaths, a substantially isotropic material, a motorized drive for moving the anisotropic head and a build plate supporting a printed part in at least three degrees of freedom, and a controller configured to control the 3D printer to build the printed part by solidifying the isotropic material along the isotropic tool paths, solidifying the anisotropic material in fiber swaths tracking a non-concentric set of anisotropic tool paths for at least a first sequence of parallel shells, solidifying the anisotropic material in fiber swaths tracking an outer concentric set of anisotropic tool paths for at least a second sequence of parallel shells.

Claims

1. A 3D printer for additive manufacturing of a part, comprising:

an anisotropic solidifying head configured to solidify, along anisotropic fill toolpaths, fiber swaths from a supply of anisotropic fiber reinforced material including a plurality of fiber strands extending continuously within a matrix material, the fiber swaths having an anisotropic characteristic oriented relative to a trajectory of the anisotropic fill toolpaths;

an isotropic solidifying head configured to solidify, along isotropic fill toolpaths, a substantially isotropic material from a supply of solidifiable isotropic material;

a motorized drive configured to relatively move at least the anisotropic solidifying head and a build plate supporting the part in at least three degrees of freedom, and

a controller configured to control the motorized drive, the anisotropic solidifying head and the isotropic solidifying head, to which the controller is operatively connected, to build the part by;

solidifying the isotropic material along the isotropic fill toolpaths,

solidifying, for each shell of a first sequence of parallel shells of the part, the anisotropic fill material in the fiber swaths tracking a non-concentric set of the anisotropic fill toolpaths, each fiber swath exhibiting the anisotropic characteristic in at least one specific direction corresponding to the trajectory of an anisotropic fill toolpath of the non-concentric set of the anisotropic fill toolpaths;

solidifying, for each shell of a second sequence of parallel shells of the part, the anisotropic fill material in the fiber swaths tracking an outer concentric set of the anisotropic fill toolpaths, each fiber swath exhibiting the anisotropic characteristic in at least one specific direction corresponding to the trajectory of an anisotropic fill toolpath of the outer concentric set of the anisotropic fill toolpaths;

each of the non-concentric set and the outer concentric set of anisotropic toolpaths being located at least partially radially outward from a centroid of the part.

2. The 3D printer according to claim 1, wherein the non-concentric set of anisotropic toolpaths includes a quasi-isotropic set of anisotropic fill toolpaths forming a laminate having a partially isotropic in-shell behavior among three or more shells, and wherein the controller is further configured to control the motorized drive, the anisotropic solidifying head and the isotropic solidifying head to build the part by solidifying the anisotropic fill material in the fiber swaths tracking the quasi-isotropic set of anisotropic fill toolpaths for at least the first sequence of parallel shells.

3. The 3D printer according to claim 2, wherein the controller is further configured to control the motorized drive, the anisotropic solidifying head, and the isotropic solidifying head to build the part by solidifying the anisotropic fill material in the fiber swaths tracking the quasi-isotropic set of anisotropic fill toolpaths for at least an additional sequence of parallel shells separated from the first sequence of parallel shells by a plurality of shells each including isotropic material.

4. The 3D printer according to claim 1, wherein the non-concentric set of anisotropic toolpaths includes a set of complementary anisotropic fill toolpaths of substantially similar areal distribution, the complementary anisotropic fill toolpaths forming a laminate having a combined in-shell behavior among two or more shells, wherein the controller is further configured to control the motorized drive, the anisotropic solidifying head and the isotropic solidifying head to build the part by solidifying the anisotropic fill material in the fiber swaths tracking the set of complementary anisotropic fill toolpaths for at least the first sequence of parallel shells.

5. The 3D printer according to claim 1, wherein the controller is further configured to control the motorized drive, the anisotropic solidifying head and the isotropic solidifying head to build the part by solidifying the anisotropic fill material in the fiber swaths tracking an inner concentric set of anisotropic fill toolpaths for the at least one of the first or second sequence of parallel shells, the inner concentric set of anisotropic toolpaths being located surrounding one or more negative contours or through hole within the part.

6. The 3D printer according to claim 1, wherein the controller is further configured to control the motorized drive, the anisotropic solidifying head and the isotropic solidifying head to build the part by solidifying the anisotropic fill material in the fiber swaths tracking an inner concentric set of anisotropic fill toolpaths for the at least one of the first or second sequence of parallel shells, the inner concentric set of anisotropic toolpaths being located looping an envelope shape including at least two or more negative contours or through holes within the part.

7. The 3D printer according to claim 1, wherein the controller is further configured to control the motorized drive, the anisotropic solidifying head and the isotropic solidifying head to build the part by solidifying the anisotropic fill material in the fiber swaths tracking a cellular infill pattern of anisotropic fill toolpaths for the at least one of the first or second sequence of parallel shells, the cellular infill pattern of anisotropic toolpaths forming repeating and cellular walls of the anisotropic fill material within the part.

8. The 3D printer according to claim 1, wherein the controller is further configured to control the motorized drive, the anisotropic solidifying head and the isotropic solidifying head to build the part by solidifying the anisotropic fill material in the fiber swaths tracking a self-crossing pattern of anisotropic fill toolpaths for the at least one of the first or second sequence of parallel shells, the self-crossing pattern of anisotropic toolpaths overlapping anisotropic solidification of the fiber swaths within a same shell or layer.