Method and apparatus for continuous composite three-dimensional printing

• US 9,511,543 B2
• Filed: 08/24/2013
• Issued: 12/06/2016
• Est. Priority Date: 08/29/2012
• Status: Active Grant

• Current Assignee: Continuous Composites Inc.
• Original Assignee: CC3D LLC
• Inventors: Tyler, Kenneth
• Primary Examiner(s): Yi, Stella
• Application Number:
  US13/975,300
• Publication Number:
  US 20140061974A1
• Time in Patent Office: 1,200 Days
• US Class Current: 1/1
• 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:

extruding through one or more openings at least one path comprising at least one primary material and at least one secondary material;

wherein the at least one primary material comprises a liquid material,

wherein the at least one secondary material comprises at least one strand, and

wherein the at least one primary material and the at least one secondary material are extruded contemporaneously;

encasing at least a portion of the at least one secondary material in the at least one primary material;

coupling a portion of the at least one path to an anchor point;

pulling the at least one path through the one or more openings by at least one of moving the one or more openings and moving the anchor point;

adjusting orientation of the at least one path relative to the one or more openings to adjust the shape of the at least one path;

hardening at least a portion of the at least one primary material; and

forming at least a portion of the three-dimensional object from the at least one path as the at least one path is extruded.

2. The method of claim 1, further comprising:

manipulating the at least one path before hardening the at least one primary material.

3. The method of claim 2, wherein the at least one path has a hardened portion and a non-hardened portion, and wherein the method further comprises manipulating the at least one path so that the hardened portion and the non-hardened portion overlap.

4. The method of claim 1, further comprising:

cutting the at least one secondary material at least one of;

before extrusion,

during extrusion, and

after extrusion of the at least one secondary material.

5. The method of claim 1, wherein the method further comprises applying tension to the at least one path.

6. The method of claim 1, wherein the at least one primary material is hardened as the at least one primary material is extruded from the one or more openings.

7. The method of claim 1, wherein the hardening of the at least one primary material comprises altering the state of the at least one primary material by at least one of the following:

UV radiation, microwave radiation, laser, electron beam, infrared radiation, natural light, chemical compound, heating, and cooling.

8. The method of claim 1, further comprising:

feeding the at least one secondary material into an extruder; and

coordinating the extrusion of the at least one primary material and the at least one secondary material such that the at least one path has a desired ratio of the at least one primary material to the at least one secondary material.

9. The method of claim 1, wherein the at least one primary material comprises multiple materials.

10. The method of claim 1, wherein the at least one secondary material comprises multiple materials.

11. The method of claim 1, wherein the at least one secondary material comprises multiple strands.

12. The method of claim 1, wherein the at least one secondary material comprises a material that is at least one of optically conductive, electrically conductive, and hollow.

13. The method of claim 1, wherein the extruding comprises extruding a plurality of paths.

14. The method of claim 1, wherein the at least one path is substantially void free.

15. The method of claim 1, wherein the adjusting of the orientation of the at least one path relative to the one or more openings comprises moving at least one of the one or more openings.

16. The method of claim 15, wherein the moving of the one or more openings is done by hand.

17. An automated method of manufacturing a three-dimensional object comprising:

receiving a specification related to the three-dimensional object;

extruding at least one path through an extruder comprising one or more openings based on the specification,

wherein the at least one path comprises at least one primary material and at least one secondary material,

wherein the at least one primary material comprises a liquid material,

wherein the at least one secondary material comprises at least one strand,

wherein the at least one primary material and the at least one secondary material are extruded contemporaneously, and

wherein the at least one primary material at least partially encases the at least one secondary material;

coupling a portion of the at least one path to an anchor point;

pulling the at least one path through the extruder by at least one of moving the extruder and moving the anchor point; and

forming at least a portion of the three-dimensional object from the at least one path as the at least one path is extruded.

18. The method of claim 17, further comprising:

coordinating the extrusion of the at least one primary material and the at least one secondary material based on the specification, such that the at least one path has a desired ratio of the at least one primary material to the at least one secondary material.

19. The method of claim 17, further comprising:

receiving feedback data from a sensor relating to the at least one path; and

adjusting at least one aspect of the extrusion based on the feedback data.

20. The method of claim 17, further comprising:

adjusting orientation of the at least one path relative to the one or more openings based on the specification.

21. The method of claim 20, wherein the adjusting of the orientation comprises use of at least one of a robotic arm and a gantry system.

22. The method of claim 17, wherein the at least one path has a hardened portion and a non-hardened portion, and wherein the method further comprises manipulating the at least one path so that the hardened portion and the non-hardened portion overlap.

23. The method of claim 17, wherein the one or more openings are adjustable in at least one of shape and size, and wherein the method further comprises adjusting at least one of the shape and size of at least one of the one or more openings.

24. The method of claim 17, further comprising:

cutting the at least one secondary material at least one of;

before extrusion,

during extrusion, and

after extrusion.

25. The method of claim 17, wherein the at least one primary material is hardened as the at least one path is extruded.

26. The method of claim 17, wherein the at least one secondary material comprises multiple materials.

27. The method of claim 17, wherein the at least one secondary material comprises multiple strands.

28. The method of claim 17, wherein the at least one secondary material comprises a material that is at least one of optically conductive, electrically conductive, and hollow.

29. The method of claim 17, wherein the extruded path is substantially void free.

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

extruding at least first and second paths through an extruder, each path comprising at least one primary material and at least one secondary material,

wherein the at least one primary material comprises at least one liquid material,

wherein the at least one secondary material comprises at least one strand,

wherein the at least one primary material and the at least one secondary material are extruded contemporaneously, and

wherein at least a portion of the at least one secondary material is encased in the at least one primary material;

coupling a portion of the at least first and second paths to one or more anchor points;

pulling the first and second paths through the extruder by at least one of moving the extruder and moving the one or more anchor points;

hardening at least a portion of the at least one primary material of the first path;

manipulating the first and second paths so that the hardened portion of the first path and a non-hardened portion of the second path overlap;

hardening the at least one primary material of the second path while the first and second paths are overlapping; and

forming at least a portion of a three-dimensional object from the paths as the paths are extruded.

31. The method of claim 30, wherein the at least one secondary material comprises a material that is at least one of optically conductive, electrically conductive, and hollow.

32. The method of claim 30, wherein the hardening of the first and second paths comprises altering the state of the at least one primary material by delivering energy to at least a portion of the paths.

33. The method of claim 32, wherein the energy comprises at least one of UV radiation, microwave radiation, laser, electron beam, infrared radiation, natural light, and heat.

34. The method of claim 32, further comprising:

adjusting at least one of the angle, direction, and intensity of the energy.

35. The method of claim 30, further comprising:

cutting at least a portion of at least first and second paths at least one of;

before extrusion,

during extrusion, and

after extrusion; and

changing the composition of the at least one secondary material by at least one of adding an additional strand and replacing the strand with a different strand.

36. The method of claim 30, wherein tension is applied to the paths coupled to the one or more anchor points.

37. The method of claim 30, wherein the first and second paths are substantially void free.

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

extruding through one or more openings at least one path comprising at least one primary material and at least one secondary material,

wherein the at least one primary material comprises a liquid material, and

wherein the at least one secondary material comprises at least one strand,

encasing at least a portion of the at least one secondary material in the at least one primary material;

coupling a portion of the at least one path to an anchor point;

pulling the at least one path through the one or more openings by at least one of moving the one or more openings and moving the anchor point;

hardening at least a portion of the at least one primary material as the at least one path is extruded from the one or more openings; and

forming at least a portion of the three-dimensional object from the at least one path as the at least one path is extruded.

39. The method of claim 38, wherein the hardening of the at least one primary material comprises delivering targeted energy to the at least one path adjacent to the one or more openings.

40. The method of claim 39, wherein the targeted energy comprises at least one of UV radiation, microwave radiation, laser, electron beam, infrared radiation, natural light, and heat.

41. The method of claim 39, wherein the targeted energy is delivered intermittently to the at least one path adjacent to the one or more openings.