Three dimensional printing of composite reinforced structures

Patent metadata

Field	Value
Publication number	US-12589547-B2
Application number	US-202418630010-A
Country	US
Kind code	B2
Filing date	Apr 9, 2024
Priority date	Mar 22, 2013
Publication date	Mar 31, 2026
Grant date	Mar 31, 2026

Abstract

Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into a conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.

First claim

The invention claimed is:

1 . A three-dimensional printer, comprising:
a first co-extrusion die comprising a first opening for a continuous core filament and a second opening for a first matrix material, the first co-extrusion die constructed and arranged to apply the first matrix material as coating on the continuous core filament to produce a first matrix-coated continuous core filament; a first exit die constructed and arranged to pass the first matrix-coated continuous core filament; a second co-extrusion die comprising a first opening adapted to receive the first matrix-coated continuous core filament and a second opening for a second matrix material, the second coextrusion die adapted to coat the first matrix-coated continuous core filament in the second matrix material to produce a double-coated continuous core filament; a second exit die constructed and arranged to pass the double-coated continuous core filament; and a first set of dispersion rollers disposed upstream of the first co-extrusion die.

2 . The printer of claim 1 , further comprising a cooling element disposed between the first co-extrusion die and the second co-extrusion die.

3 . The printer of claim 1 , further comprising a cooling tube operatively coupled to the cooling element and dimensioned to receive the first matrix-coated continuous core filament.

4 . The printer of claim 3 , wherein the first exit die is coupled to an entrance of the cooling tube.

5 . The printer of claim 3 , further comprising a forming die coupled to an entrance of the cooling tube.

6 . The printer of claim 1 , further comprising a second set of dispersion rollers disposed at an exit of the first co-extrusion die.

7 . The printer of claim 1 , wherein the first matrix material and the second matrix material are a same material.

8 . The printer of claim 1 , wherein the first matrix material and the second matrix material are a different material.

Assignees

• Markforged Inc

Inventors

• Mark Gregory Thomas
• Gozdz Antoni S

Classifications

• B29K2307/04

  Carbon · CPC title

• B29K2105/106

  longitudinally · CPC title

• B29K2077/00

  Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title