Multilayer fiber reinforcement design for 3d printing

Patent metadata

Field	Value
Publication number	US-2017334136-A1
Application number	US-201715633182-A
Country	US
Kind code	A1
Filing date	Jun 26, 2017
Priority date	Mar 22, 2013
Publication date	Nov 23, 2017
Grant date	—

Abstract

According to at least one aspect, embodiments of the invention provide a 3D printer comprising an anisotropic head that solidifies, along anisotropic toolpaths, fiber swaths having an anisotropic characteristic oriented relative to a trajectory of the anisotropic tool paths, an isotropic head that solidifies, along isotropic toolpaths, a substantially isotropic material, a motorized drive for moving the anisotropic head and a build plate supporting a printed part in at least three degrees of freedom, and a controller configured to control the 3D printer to build the printed part by solidifying the isotropic material along the isotropic tool paths, solidifying the anisotropic material in fiber swaths tracking a non-concentric set of anisotropic tool paths for at least a first sequence of parallel shells, solidifying the anisotropic material in fiber swaths tracking an outer concentric set of anisotropic tool paths for at least a second sequence of parallel shells.

First claim

What is claimed is:

1 . A 3D printer for additive manufacturing of a part, comprising:
an anisotropic solidifying head that solidifies, along anisotropic fill toolpaths, fiber swaths from a supply of anisotropic fiber reinforced material including a plurality of fiber strands extending continuously within a matrix material, the fiber swaths having an anisotropic characteristic oriented relative to a trajectory of the anisotropic fill tool paths; an isotropic solidifying head that solidifies, along isotropic fill toolpaths, a substantially isotropic material from a supply of solidifiable isotropic material; a motorized drive for relatively moving at least the anisotropic solidifying head and a build plate supporting a 3D printed part in at least three degrees of freedom, and a controller, wherein the controller is configured to control the motorized drive, the anisotropic solidifying head and the isotropic solidifying head, to which the controller is operatively connected, to build the 3D printed part by:
solidifying the isotropic material along the isotropic fill tool paths,
solidifying the anisotropic fill material in fiber swaths tracking a non-concentric set of anisotropic fill tool paths for at least a first sequence of parallel shells,
solidifying the anisotropic fill material in fiber swaths tracking an outer concentric set of anisotropic fill tool paths for at least a second sequence of parallel shells,
each of the non-concentric set and the outer concentric set of anisotropic tool paths being located at least partially radially outward from a centroid of the 3D printed part.

2 . The 3D printer according to claim 1 , wherein the non-concentric set of anisotropic tool-paths includes a quasi-isotropic set of anisotropic fill tool paths forming a laminate having a partially isotropic in-shell behavior among three or more shells, and wherein the controller is further configured to control the motorized drive, the anisotropic deposition head and the isotropic solidifying head to build the 3D printed part by solidifying the anisotropic fill material in fiber swaths tracking a quasi-isotropic set of anisotropic fill tool paths for at least the first sequence of parallel shells.

3 . The 3D printer according to claim 2 , wherein the controller is further configured to control the motorized drive, the anisotropic deposition head and the isotropic solidifying head to build the 3D printed part by solidifying the anisotropic fill material in fiber swaths tracking a quasi-isotropic set of anisotropic fill tool paths for at least an additional sequence of parallel shells separated from the first sequence of parallel shells by a plurality of shells each including isotropic fill material.

4 . The 3D printer according to claim 1 , wherein the non-concentric set of anisotropic tool-paths includes a set of complementary anisotropic fill tool paths of substantially similar areal distribution, the complementary anisotropic fill tool paths forming a laminate having a combined in-shell behavior among two or more shells, wherein the controller is further configured to control the motorized drive, the anisotropic deposition head and the isotropic solidifying head to build the 3D printed part by solidifying the anisotropic fill material in fiber swaths tracking the set of complementary anisotropic fill tool paths for at least the first sequence of parallel shells.

5 . The 3D printer according to claim 1 , wherein the controller is further configured to control the motorized drive, the anisotropic deposition head and the isotropic solidifying head to build the 3D printed part by solidifying the anisotropic fill material in fiber swaths tracking an inner concentric set of anisotropic fill tool paths for at least one of the first or second sequence of parallel shells, the inner concentric set of anisotropic tool paths being located surrounding one or more negative contours or through hole within the 3D printed part.

6 . The 3D printer according to claim 1 , wherein the controller is further configured to control the motorized drive, the anisotropic deposition head and the isotropic solidifying head to build the 3D printed part by solidifying the anisotropic fill material in fiber swaths tracking an inner concentric set of anisotropic fill tool paths for at least one of the first or second sequence of parallel shells, the inner concentric set of anisotropic tool paths being located looping an envelope shape including at least two or more negative contours or through holes within the 3D printed part.

7 . The 3D printer according to claim 1 , wherein the controller is further configured to control the motorized drive, the anisotropic deposition head and the isotropic solidifying head to build the 3D printed part by solidifying the anisotropic fill material in fiber swaths tracking a cellular infill pattern of anisotropic fill tool paths for at least one of the first or second sequence of parallel shells, the cellular infill pattern of anisotropic tool paths forming repeating and cellular walls of anisotropic fill material within the 3D printed part.

8 . The 3D printer according to claim 1 , wherein the controller is further configured to control the motorized drive, the anisotropic deposition head and the isotropic solidifying head to build the 3D printed part by solidifying the anisotropic fill material in fiber swaths tracking a self-crossing pattern of anisotropic fill tool paths for at least one of the first or second sequence of parallel shells, the self-crossing pattern of anisotropic tool paths overlapping anisotropic solidification of fiber swaths within a same shell or layer.

Assignees

• Markforged Inc

Inventors

• Mark Gregory Thomas
• Woodruff Rick Bryan
• Benhaim David Steven
• Parangi Abraham Lawrence
• Sklaroff Benjamin Tsu

Classifications

• B29K2063/00

  Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29K2025/08

  Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene (B29K2055/02 takes precedence) · CPC title