Apparatus for fiber reinforced additive manufacturing

Patent metadata

Field	Value
Publication number	US-11420382-B2
Application number	US-202016840868-A
Country	US
Kind code	B2
Filing date	Apr 6, 2020
Priority date	Mar 22, 2013
Publication date	Aug 23, 2022
Grant date	Aug 23, 2022

Abstract

Methods for additive manufacturing using a three-dimensional printer including at least one linear feed mechanism and a print head positioned proximate a build platen are disclosed. The methods include a step of providing and/or feeding an unmelted fiber reinforced composite filament at a feed rate by the at least one linear feed mechanism. The methods include heating the filament to a temperature at which a matrix material therein flows within at least one rounded outlet of the print head. The methods include moving the print head and the build platen relative to one another at a printing rate. The methods include applying a spreading force to the filament between the at least one rounded outlet of the print head and the build platen. The methods include a step of controlling a differential in the feed rate and printing rate using the at least one linear feed mechanism so that the feed rate and the printing rate are substantially the same.

First claim

What is claimed is:

1. A method for additive manufacturing using a three-dimensional printer comprising at least one linear feed mechanism and a print head positioned proximate a build platen, the method comprising:
feeding an unmelted fiber reinforced composite filament to the print head at a feed rate by the at least one linear feed mechanism;
heating the filament to a temperature at which a matrix material therein flows within at least one rounded outlet of the print head;
moving the print head and the build platen relative to one another at a printing rate;
applying a spreading force to the filament between the at least one rounded outlet of the print head and the build platen; and
controlling a differential in the feed rate and printing rate using the at least one linear feed mechanism so that the feed rate and the printing rate are substantially the same.

2. The method of claim 1 , wherein one or both of the feed rate and/or printing rate are set to apply a neutral to positive tension force through a fiber strand of the filament and unmelted matrix of the filament.

3. The method of claim 1 , wherein one or both of the feed rate and/or printing rate are set to apply a neutral to positive tension force through a fiber strand of the filament and the build platen.

4. The method of claim 1 , further comprising adjusting the feed rate and/or printing rate using a controller operatively coupled to the three-dimensional printer.

5. The method of claim 4 , wherein adjusting the feed rate and/or printing rate includes adjusting the feed rate to be less than the printing rate.

6. The method of claim 1 , wherein the at least one linear feed mechanism comprises at least one of frictional rollers, a conveyor, a feeding track, a gravity feed, or a hydraulic feed.

7. The method of claim 6 , wherein the frictional rollers comprise a drive roller and an idle roller.

8. The method of claim 1 , wherein applying the spreading force includes applying the spreading force using an ironing lip or an ironing tip of the print head.

9. The method of claim 1 , further comprising cutting the fiber reinforced composite filament at a predetermined termination point.

10. A method for additive manufacturing using a three-dimensional printer comprising at least one linear feed mechanism and a print head positioned proximate a build platen, the method comprising:
providing a fiber reinforced composite filament at a feed rate to the print head, the feed rate applied by the at least one linear feed mechanism;
moving the print head and the build platen relative to one another at a printing rate;
controlling a differential in the feed rate and printing rate along the filament using the at least one linear feed mechanism so that the feed rate and printing rate are substantially the same; and
applying a spreading force to the filament between the print head and the build platen.

11. The method of claim 10 , wherein controlling the differential in the feed rate and printing rate along the filament includes absorbing the differential between the feed rate and the printing rate along the filament using the at least one linear feed mechanism.

12. The method of claim 10 , further comprising setting one or both of the feed rate and the printing rate to maintain a neutral to positive tension in the fiber reinforced composite filament between the print head and a part being printed.

13. The method of claim 10 , further comprising providing a compressive force to the fiber reinforced composite filament at a position downstream of the at least one linear feed mechanism.

14. The method of claim 10 , further comprising adjusting the feed rate and/or printing rate using a controller operatively coupled to the three-dimensional printer.

15. The method of claim 14 , wherein adjusting the feed rate and/or printing rate includes adjusting the feed rate to be less than the printing rate.

16. The method of claim 10 , wherein the at least one linear feed mechanism comprises at least one of frictional rollers, a conveyor, a feeding track, a gravity feed, or a hydraulic feed.

17. The method of claim 16 , wherein the frictional rollers comprise a drive roller and an idle roller.

18. The method of claim 10 , wherein applying the spreading force includes applying the spreading force using an ironing lip or an ironing tip of the print head.

19. The method of claim 10 , further comprising cutting the fiber reinforced composite filament at a predetermined termination point.

Assignees

• Markforged Inc

Inventors

• Mark Gregory Thomas
• Gozdz Antoni S

Classifications

• B33Y70/10 Primary

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B29C64/295

  Heating elements · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29C70/20

  oriented in a single direction, e.g. roofing or other parallel fibres {(B29C70/083, B29C70/226 take precedence)} · CPC title

• B29C64/321

  Feeding · CPC title