# US 10,766,195 B2 · Additive manufacturing fiber composites and related systems and methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,766,195 B2 - Document ID: US10766195B2 - Status: Granted - Kind: B2 - Application number: 15/726,283 - Filed: 2017-10-05 - Published: 2019-04-11 - Granted: 2020-09-08 - Earliest claimed: 2017-10-05 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Michael Patrick Kozar; Mark Stewart Wilenski; Samuel F. Harrison - Web page: https://patentgrep.com/patent/US10766195B2 ## CPC - B29C 64/291: for operating globally, e.g. together with selectively applied activators or inhibitors - B29C 35/0805: {using electromagnetic radiation} - B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM] - B29C 64/129: characterised by the energy source therefor, e.g. by global irradiation combined with a mask - B33Y 10/00: Processes of additive manufacturing - B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials - B29B 15/122: {with a matrix in liquid form, e.g. as melt, solution or latex} - B29B 15/14: of filaments or wires - 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 - B29C 64/188: involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control (surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00) - B29C 64/209: Heads; Nozzles - B29C 64/295: Heating elements - B29C 2035/0844: {using X-ray} - B29C 2035/085: {using gamma-ray} - B29K 2101/12: Thermoplastic materials - B29K 2105/08: of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 99/00: Subject matter not provided for in other groups of this subclass - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract Additive manufacturing fiber composites comprise a bundle of elongate fibers and a matrix material that holds or encompasses the elongate fibers of the additive manufacturing fiber tow. The matrix material includes an energy-emissive dopant that emits a curing energy in response to receiving an activating energy. The curing energy effects curing of the solidifiable matrix material so that it solidifies to a rigid or semi-rigid matrix material. Methods of additively manufacturing an article include dispensing an additive manufacturing fiber tow, a solidifiable matrix material, and an energy-emissive dopant to form a solidifiable composite, and applying the activating energy to the energy-emissive dopant to activate the energy-emissive dopant to emit the curing energy. Systems to additively manufacturing an article may be configured to employ such additive manufacturing fiber composites and/or methods. ## Claims ### Claim 1 A method of additively manufacturing an article, comprising: dispensing an additive manufacturing fiber tow, a photopolymer matrix material, and an energy-emissive dopant, wherein the energy-emissive dopant emits a curing energy in response to receiving an activating energy, and the curing energy effects curing of the photopolymer matrix material; and applying the activating energy to the energy-emissive dopant to activate the energy-emissive dopant to emit the curing energy, wherein the activating energy is different than the curing energy and penetrates the additive manufacturing fiber tow. ### Claim 2 (depends on 1) The method of claim 1, wherein dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant includes arranging the additive manufacturing fiber tow in an article configuration with the photopolymer matrix material and the energy-emissive dopant. ### Claim 3 (depends on 2) The method of claim 2, wherein applying the activating energy to the energy-emissive dopant includes applying the activating energy to the energy-emissive dopant with the additive manufacturing fiber tow and the photopolymer matrix material in the article configuration. ### Claim 4 (depends on 1) The method of claim 1, wherein applying the activating energy to the energy-emissive dopant includes applying the activating energy to the energy-emissive dopant without the additive manufacturing fiber tow. ### Claim 5 (depends on 1) The method of claim 1, wherein the photopolymer matrix material includes a non-reactive matrix component and a resin and the energy-emissive dopant is included in the non-reactive matrix component, wherein the method further comprises mixing the resin with the non-reactive matrix component and the energy-emissive dopant, and wherein dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant includes applying the photopolymer matrix material and the energy-emissive dopant to the additive manufacturing fiber tow. ### Claim 6 (depends on 1) The method of claim 1, wherein the activating energy includes x-ray radiation. ### Claim 7 (depends on 1) The method of claim 1, wherein the energy-emissive dopant includes nanoparticles. ### Claim 8 (depends on 1) The method of claim 1, wherein the energy-emissive dopant emits the curing energy while receiving the activating energy. ### Claim 9 (depends on 1) The method of claim 1, wherein the energy-emissive dopant continues to emit the curing energy subsequent to application of the activating energy. ### Claim 10 (depends on 1) The method of claim 1, wherein the activating energy includes ionizing radiation to penetrate the additive manufacturing fiber tow and the photopolymer matrix material to activate the energy-emissive dopant. ### Claim 11 (depends on 1) The method of claim 1, wherein the additive manufacturing fiber tow with the photopolymer matrix material and the energy-emissive dopant that emits the curing energy correspond to a first additive manufacturing fiber tow with a first solidifiable matrix material and a first energy-emissive dopant that emits a first curing energy, respectively, wherein the first curing energy effects curing of the first solidifiable matrix material at a first cure rate, and wherein the method further comprises dispensing a second additive manufacturing fiber tow on the first additive manufacturing fiber tow with a second solidifiable matrix material and a second energy-emissive dopant, wherein the second energy-emissive dopant emits a second curing energy in response to receiving the activating energy, and the second curing energy effects curing of the second solidifiable matrix material at a second cure rate that is different than the first cure rate. ### Claim 12 (depends on 1) The method of claim 1, wherein dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant includes dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant as an elongate additive manufacturing fiber composite, in which the energy-emissive dopant is distributed only within a center region of the elongate additive manufacturing fiber composite. ### Claim 13 (depends on 1) The method of claim 1, wherein dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant includes dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant as an elongate additive manufacturing fiber composite, in which the energy-emissive dopant is distributed in one or more concentric arrangements within the elongate additive manufacturing fiber composite. ### Claim 14 (depends on 1) The method of claim 1, wherein dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant includes dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant as an elongate additive manufacturing fiber composite, in which the energy-emissive dopant is distributed in multiple radial arrangements within the elongate additive manufacturing fiber composite. ### Claim 15 (depends on 1) The method of claim 1, wherein dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant includes dispensing the additive manufacturing fiber tow, the photopolymer matrix material, and the energy-emissive dopant as an elongate additive manufacturing fiber composite with a flat configuration, in which the energy-emissive dopant is distributed in a central planar region of the elongate additive manufacturing fiber composite. ### Claim 16 A method of additively manufacturing an article, comprising: dispensing a solidifiable elongate additive manufacturing fiber composite comprising a photopolvmer matrix material, an additive manufacturing fiber tow within the photopolvmer matrix material, a first distribution of a first energy-emissive dopant within the photopolvmer matrix material, and a second distribution of a second energy-emissive dopant within the photopolvmer matrix material, wherein the first energy-emissive dopant and the second energy-emissive dopant emit a curing energy in response to receiving an activating energy, wherein the curing energy effects curing of the photopolvmer matrix material, wherein the activating energy is different than the curing energy and penetrates the additive manufacturing fiber tow, and wherein the first energy-emissive dopant and the second energy-emissive dopant emit the curing energy at different rates; and applying the activating energy to the first energy-emissive dopant and to the second energy-emissive dopant to activate the first energy-emissive dopant and the second energy-emissive dopant to emit the curing energy. ### Claim 17 (depends on 16) The method of claim 16, wherein the first distribution is within an outer region of the solidifiable elongate additive manufacturing fiber composite, wherein the second distribution is within a central region of the solidifiable elongate additive manufacturing fiber composite, and wherein the second energy-emissive dopant emits the curing energy at a higher rate than the first energy-emissive dopant. ### Claim 18 (depends on 16) The method of claim 16, wherein dispensing the solidifiable elongate additive manufacturing fiber composite includes arranging the solidifiable elongate additive manufacturing fiber composite in an article configuration. ### Claim 19 (depends on 18) The method of claim 18, wherein applying the activating energy includes applying the activating energy to the first energy-emissive dopant and to the second energy-emissive dopant with the solidifiable elongate additive manufacturing fiber composite in the article configuration. ### Claim 20 (depends on 16) The method of claim 16, wherein applying the activating energy includes applying the activating energy to the first energy-emissive dopant and to the second energy-emissive dopant prior to dispensing the solidifiable elongate additive manufacturing fiber composite.