METHOD AND APPARATUS FOR CONTINUOUS COMPOSITE THREE-DIMENSIONAL PRINTING

• US 20190322035A1
• Filed: 07/02/2019
• Published: 10/24/2019
• Est. Priority Date: 08/29/2012
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: Continuous Composites Inc.
• Inventors: TYLER, KENNETH LYLE
• Granted Patent: US 10,759,109 B2
• Time in Patent Office: 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. An apparatus for additively manufacturing of a three-dimensional object, comprising:

an extruder configured to emit a continuous strand encased in a primary material; and

at least one of a robot arm and a gantry system configured to move the extruder during emission such that the continuous strand is pulled from the extruder by the movement during at least a portion of the manufacturing of the three-dimensional object.

2. The apparatus of claim 1, wherein the extruder is configured to receive the primary material separately from the continuous strand.

3. The apparatus of claim 1, further including a means for causing the primary material to harden, the means being aimed at the primary material emitting from the extruder.

4. The apparatus of claim 3, wherein the means includes a source of energy.

5. The apparatus of claim 4, wherein the source of energy is light.

6. The apparatus of claim 5, wherein the source is one of a UV light and a laser.

7. The apparatus of claim 3, wherein the means is attached to and moves with the extruder.

8. The apparatus of claim 1, further including a control unit programmed to cause the at least one of the robot arm and the gantry system to move the extruder during emission, such that the continuous strand is pulled from the extruder by the movement during the at least a portion of the manufacturing of the three-dimensional object.

14. The apparatus of claim 1, further including a control unit programmed to cause the at least one of the robot arm and the gantry system to move the extruder during emission and for coordinating activation of the means for casing the primary material to harden with the movement.

9. An apparatus for additively manufacturing of a three-dimensional object, comprising:

an extruder configured to emit a continuous strand encased in a primary material;

at least one of a robot arm and a gantry system configured to move the extruder; and

a means for causing the primary material to harden after emission from the extruder, the means being attached to and moved with the extruder.

10. The apparatus of claim 9, wherein the extruder is configured to receive the primary material separately from the continuous strand.

11. The apparatus of claim 9, wherein the means includes a source of energy.

12. The apparatus of claim 11, wherein the source of energy is light.

13. The apparatus of claim 12, wherein the source is one of a UV light and a laser.

15. An apparatus for additively manufacturing of a three-dimensional object, comprising:

an extruder configured to separately receive a continuous strand and a primary material, and to emit the continuous strand coated in the primary material; and

a means configured to cause the primary material to harden after emission from the extruder.

16. The apparatus of claim 15, wherein the means includes a source of energy.

17. The apparatus of claim 16, wherein the source of energy is light.

18. The apparatus of claim 17, wherein the source is one of a UV light and a laser.

19. The apparatus of claim 15, further including a control unit programmed to activate the means configured to cause the primary material to harden in cooperation with emission of the continuous strand coated in the primary material.

20. The apparatus of claim 15, wherein the primary material is a thermoset resin.