ADDITIVE MANUFACTURING SYSTEM WITH LAYERS OF REINFORCING MESH

• US 20170129179A1
• Filed: 11/11/2015
• Published: 05/11/2017
• Est. Priority Date: 11/11/2015
• Status: Active Grant

• Current Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Original Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Inventors: Mandel, Barry P., Mantell, David A., Liu, Chu-Heng, Kanungo, Mandakini
• Granted Patent: US 11,654,623 B2
• Time in Patent Office: Days
• 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 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/314 Preparation
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• 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: 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 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

A three-dimensional object printer includes a controller that operates at least one ejector to place a layer of photopolymer material on a substrate. The controller is configured to cure the ejected photopolymer layer partially and position fiber on the cured layer before continuing to eject photopolymer material onto the fibers. The fibers can be loose or organized into a mesh. The pieces of mesh position on a cured layer can be pre-cut or a cutting device can be operated to cut pieces of mesh having a shape that corresponds to the shape of the layer of photopolymer material. The fibers reinforce the layers of photopolymer material and add strength and durability to the overall part being formed with the photopolymer material.

Claims

1. An additive manufacturing method for embedding fibers in a three-dimensional structure comprising:

operating with a controller at least one ejector in a plurality of ejectors to form at least one layer of a photopolymer material on a substrate;

operating with the controller a source of ultraviolet (UV) radiation to cure the at least one layer of photopolymer partially;

operating with the controller an actuator to position fibers onto a top surface of the at least one layer of partially cured photopolymer; and

operating with the controller the at least one ejector to eject additional photopolymer material onto the fibers to form at least one other layer of photopolymer material on the fibers.

2. The method of claim 1, the positioning of the fibers further comprising:

operating the actuator with the controller to position at least one piece of mesh onto the top surface of the at least one layer of cured photopolymer.

3. The method of claim 2 further comprising:

operating with the controller a cutting device to cut the at least one piece of mesh into a shape that corresponds to a portion of the at least one layer of photopolymer material.

4. The method of claim 3 further comprising:

generating with an optical sensor image data of the at least one layer of the photopolymer material; and

generating with the controller signals for operating the cutting device and the at least one ejector with reference to the image data generated by the optical sensor.

5. The method of claim 3 further comprising:

generating with the controller signals for operating the cutting device with reference to image data used to operate the at least one ejector to form the at least one layer of photopolymer material.

6. The method of claim 3, the operation of the cutting device further comprising:

operating with the controller a laser to cut the at least one piece of mesh.

7. The method of claim 3, the operation of the cutting device further comprising:

operating with the controller a blade to cut the at least one piece of mesh.

8. The method of claim 1 further comprising:

operating with the controller a second actuator to press a plate or a roller into the at least one other layer and the at least one piece of mesh material to level a top surface of the at least one other layer and the at least one piece of mesh material.

9. The method of claim 1 further comprising:

operating a leveler with the controller to remove a portion of the at least one other layer of the photopolymer material.

10. The method of claim 2, the operation of the actuator further comprising:

operating a robotic arm with the controller to move the at least one piece of mesh.

11. The method of claim 10, the operation of the robotic arm further comprising:

operating the robotic arm with the controller to orient a first piece of mesh in a first orientation before positioning the first piece of mesh on the top surface of the partially cured photopolymer; and

operating the robotic arm with the controller to orient a second piece of mesh in a second orientation that is different than the first orientation before positioning the second piece of mesh on the top surface of the partially cured photopolymer.

12. The method of claim 1, the positioning of the fibers further comprising:

operating the actuator with the controller to dispense fibers from a nozzle onto the top surface of the partially cured photopolymer material.

13. A system for forming a three-dimensional structure using an additive manufacturing method comprising:

a substrate;

a plurality of ejectors configured to eject drops of photopolymer material towards the substrate;

a source of ultraviolet (UV) radiation that emits radiation to cure the photopolymer material ejected from the plurality of ejectors;

an actuator configured to position fibers on photopolymer material supported by the substrate; and

a controller operatively connected to the plurality of ejectors, the source of radiation, and the actuator, the controller being configured to;

operate at least one ejector in the plurality of ejectors to form at least one layer of the photopolymer material on the substrate,

operate the source of UV radiation to cure the at least one layer of photopolymer material partially;

operate the actuator to position fibers on a top surface of the at least one layer of the partially cured photopolymer material; and

operate the plurality of ejectors to eject additional photopolymer material onto the fibers to form at least one other layer of photopolymer material on the fibers.

14. The system of claim 13, the controller being further configured to:

operating the actuator to position at least one piece of mesh onto the top surface of the at least one layer of partially cured photopolymer.

15. The system of claim 14 further comprising:

a cutting device; and

the controller being further configured to operate the cutting device to cut the at least one piece of mesh into a shape that corresponds to a portion of the at least one layer of photopolymer material.

16. The system of claim 15 further comprising:

an optical sensor configured to generate image data of the at least one layer of the photopolymer material; and

the controller is further configured to generate signals for operating the cutting device and the plurality of ejectors with reference to the image data generated by the optical sensor.

17. The system of claim 15, the controller being further configured to operate the cutting device with reference to image data used to operate the plurality of ejectors to form the at least one layer of photopolymer material.

18. The system of claim 15, the cutting device further comprising:

a laser configured to cut the at least one piece of mesh.

19. The system of claim 15, the cutting device further comprising:

a blade configured to cut the at least one piece of mesh.

20. The system of claim 13 further comprising:

a second actuator; and

the controller being operatively connected to the second actuator, the controller being further configured to operate the second actuator to press a plate or a roller into the at least one other layer and the at least one piece of mesh to level a top surface of the at least one other layer and the at least one piece of mesh.

21. The system of claim 13 further comprising:

a leveler; and

the controller being operatively connected to the leveler, the controller being further configured to operate the leveler to remove a portion of the at least one other layer of the photopolymer material.

22. The system of claim 14, the controller being configured to operate the actuator by operating a robotic arm to move the at least one piece of mesh.

23. The system of claim 22, the controller being further configured to operate the robotic arm by operating the robotic arm to orient a first piece of mesh in a first orientation before positioning the first piece of mesh on the top surface of the cured photopolymer;

and

operate the robotic arm to orient a second piece of mesh in a second orientation that is different than the first orientation before positioning the second piece of mesh on the top surface of the partially cured photopolymer.

24. The system of claim 13, the controller being further configured to operate the actuator by operating the actuator to dispense fibers from a nozzle onto the top surface of the partially cured photopolymer material.