Multilayer fiber reinforcement design for 3D printing

• US 10,696,039 B2
• Filed: 11/09/2017
• Issued: 06/30/2020
• Est. Priority Date: 03/22/2013
• Status: Active Grant

• Current Assignee: MarkForged, Inc
• Original Assignee: MarkForged, Inc
• Inventors: Mark, Gregory Thomas, Woodruff, Rick Bryan, Parangi, Abraham Lawrence, Benhaim, David Steven, Sklaroff, Benjamin Tsu
• Primary Examiner(s): Mackey, James P
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US15/808,081
• Publication Number:
  US 20180072040A1
• Time in Patent Office: 964 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 64/386 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 70/16 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: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/35134 3-D cad-cam
• CPC Class Codes: G05B 2219/49007 Making, forming 3-D object, model, surface
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method comprising receiving a first 3D toolpath defining a fill material curved shell, receiving first 2D toolpaths defining support material flat shells, receiving a second 3D toolpath defining a long fiber composite material curved shell, the long fiber composite material including a filament having a matrix embedding fibers having a length longer than two times a diameter of the filament, actuating a fill material deposition head to trace the first 3D toolpath to deposit the fill material curved shell non-parallel to a printing substrate, actuating a support material deposition head to trace the first 2D toolpaths to deposit support material in a succession of substantially flat shells, and actuating a long fiber deposition head to trace the second 3D toolpath non-parallel to the printing substrate to deposit the long fiber composite material curved shell to enclose at least a portion of the fill material curved shell.

Claims

1. A method for depositing a 3D printed part with a composite material 3D printer, comprising:

receiving a first 3D toolpath defining a fill material curved shell;

receiving first 2D toolpaths defining support material flat shells;

receiving a second 3D toolpath defining a long fiber composite material curved shell, the long fiber composite material curved shell including a filament having a matrix embedding fibers having a length longer than two times a diameter of the filament;

actuating a fill material deposition head to trace the first 3D toolpath to deposit the fill material curved shell at least in part non-parallel to a printing substrate;

actuating a support material deposition head to trace the first 2D toolpaths to deposit support material in a succession of substantially flat shells; and

actuating a long fiber deposition head to trace the second 3D toolpath at least in part non-parallel to the printing substrate to deposit the long fiber composite material curved shell to enclose at least a portion of the fill material curved shell.

2. The method according to claim 1, further comprising:

actuating one of the support material deposition head and the fill material deposition head to deposit the printing substrate upon a build platform.

3. The method according to claim 2, further comprising:

actuating the build platform to rotate in at least one degree of freedom additional to degrees of freedom of one of the support material deposition head and the fill material deposition head.

4. The method according to claim 2, further comprising:

actuating the build platform to rotate through 180 degrees or more in at least one degree of freedom additional to degrees of freedom of one of the support material deposition head and the fill material deposition head to form at least one of a substantially rotationally symmetric printing substrate and a substantially rotationally symmetric fill material deposition.

5. The method according to claim 1, further comprising:

actuating the support material deposition head to trace the first 2D toolpaths to deposit a separable or dissolvable material in a succession of shells forming a curved printing substrate.

6. The method according to claim 1, wherein the filament of the long fiber composite material curved shell includes a prepreg filament including the matrix embedding fibers having a length of between 0.6-15 mm, and between two and ten times longer than a diameter of the prepreg filament.

7. The method according to claim 1, wherein the printing substrate includes at least one rotationally symmetric portion.