Method and apparatus for continuous composite three-dimensional printing

• US 9,987,798 B2
• Filed: 09/16/2016
• Issued: 06/05/2018
• 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 KIM
• Application Number:
  US15/267,956
• Publication Number:
  US 20170008235A1
• Time in Patent Office: 627 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. A method of manufacturing of a three-dimensional object, comprising:

directing a curable liquid material to a nozzle;

directing a continuous strand material to the nozzle;

discharging from the nozzle a path of composite material containing the continuous strand material at least partially coated with the curable liquid material;

bonding an end point of the path of composite material to an anchor; and

moving the nozzle away from the anchor during discharging to pull the path of composite material out of the nozzle.

2. The method of claim 1, wherein bonding the end point of the path of composite material to the anchor includes:

placing the end point of the path of composite material on the anchor; and

aiming a curing device at the path of composite material on the anchor.

3. The method of claim 2, wherein aiming the curing device includes aiming at least one UV light.

4. The method of claim 3, wherein aiming the at least one UV light includes aiming a plurality of lights from different angles around the nozzle.

5. The method of claim 3, wherein aiming the at least one UV light includes aiming the at least one UV light from only a trailing side of the nozzle.

6. The method of claim 1, wherein discharging from the nozzle the path of composite material includes discharging the path of composite material through a nozzle orifice having a diameter of about 2 mm.

7. The method of claim 6, wherein the continuous strand material includes a plurality of strands arranged in at least one of a tow, a roving, and a weave.

8. The method of claim 1, wherein directing the curable liquid material to the nozzle includes directing a filler material at least partially coated in the curable liquid material to the nozzle.

9. The method of claim 8, wherein the filler material includes pieces of fibers.

10. The method of claim 1, wherein the continuous strand material is hollow.

11. The method of claim 1, further including:

curing a first portion of the path of composite material;

overlapping the first portion of the path of composite material with a second portion of the path of composite material that is uncured; and

curing the second portion of the path of composite material while the first and second portions of the path of composite material are overlapped.

12. The method of claim 1, wherein the overlapping includes wrapping the second portion of the path of composite material around the first portion of the path of composite material.

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

directing a curable liquid material to a nozzle;

directing a continuous strand material to the nozzle;

discharging from the nozzle a path of composite material containing the continuous strand material at least partially coated with the curable liquid material;

bonding an end point of the path of composite material to an anchor;

moving the nozzle during discharging to cause the path of composite material to extend away from the anchor; and

exposing the curable liquid material in the path of composite material to a cure energy while the nozzle is moving such that the path of composite material is hardened at a fixed location in three-dimensional space without support at locations between the anchor and the nozzle.

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

directing a curable liquid material to a nozzle;

directing a continuous strand material to the nozzle;

discharging from the nozzle a path of composite material containing the continuous strand material at least partially coated with the curable liquid material;

curing the curable liquid material in the path of composite material; and

moving the nozzle during discharging to create tension in the continuous strand material that remains after curing of the composite material.

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

directing a curable liquid material to a nozzle;

directing a continuous strand material to the nozzle;

directing flakes of fiber to the nozzle;

discharging from the nozzle a path of composite material containing the continuous strand material and the flakes of fiber at least partially coated with the curable liquid material;

moving the nozzle during discharging to create the three-dimensional object; and

curing the curable liquid material in the path of composite material.

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

directing a curable liquid material to a nozzle;

directing a continuous strand material to the nozzle;

discharging from the nozzle a path of composite material containing the continuous strand material at least partially coated with the curable liquid material;

aiming a curing device at the path of discharged composite material to cure the curable liquid material;

moving the nozzle during discharging to create the three-dimensional object; and

moving the curing device together with the nozzle.

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

directing a curable liquid material to a nozzle;

directing a continuous strand material to the nozzle;

discharging from the nozzle a path of composite material containing the continuous strand material at least partially coated with the curable liquid material;

curing the curable liquid material in the path of composite material;

moving the nozzle during discharging to create the three-dimensional object; and

selectively cutting the continuous strand material before the continuous strand material reaches the nozzle such that at least one portion of the path discharging from the nozzle contains only the curable liquid material.

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

directing a curable liquid material to a nozzle;

directing a continuous strand material to the nozzle;

discharging from the nozzle a path of uncured composite material containing the continuous strand material at least partially coated with the curable liquid material;

adjusting a trajectory of the path of uncured composite material to a new location after discharge from the nozzle; and

curing the curable liquid material in the path of uncured composite material at the new location after adjusting.

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

discharging from a nozzle a first path of composite material;

curing a first portion of the first path of composite material, leaving a second portion of the first path of composite material at least partially uncured;

discharging a second path of composite material adjacent the first path of composite material,

wherein the composite material of each of the first and second paths contain a continuous strand material at least partially coated with a curable liquid material;

curing the second path of composite material;

mechanically interlocking the second portion of the first path of composite material with the cured second path of composite material; and

curing the second portion of the first path of composite material while the second portion of the first path of composite material is mechanically interlocked with the cured second path of composite material.

20. The method of claim 19, wherein discharging from the nozzle the first path of composite material and the second path of composite material includes simultaneously discharging the first and second paths of composite material.