Devices and methods for additive manufacturing using flexible filaments
AssigneeUnited States of America as represented by the Administrator of NASA
InventorsJohn M. Gardner, Christopher J. Stelter, Katherine A. Fotion, Jae-Woo Kim, Godfrey Sauti, Emilie J. Siochi
Life of this patent
Estimating the term…
Abstract
A method of fabricating (printing) parts utilizing flexible filaments includes anchoring a portion of a flexible filament to a substrate. A length of flexible filament is extended over the substrate while the flexible filament is in tension to thereby avoid buckling of the flexible filament. The flexible filament may comprise a thermoplastic material and fibers or other reinforcing materials whereby composite 3D parts can be fabricated.
Claims19
A method of depositing flexible filament onto a substrate to form objects, the method comprising:
- threading a flexible filament through a passageway in a heating element and through a passageway in a nozzle, wherein the flexible filament is unconstrained between a metering device and the heating element, the heating element being disposed between the nozzle and the metering device such that the flexible filament is threaded through the passageway in the heating element before being threaded through the passageway in the nozzle;
- extending a first portion of the flexible filament from the nozzle through an opening in a compaction foot disposed between the nozzle and the substrate, wherein the compaction foot is configured to move vertically independent of the nozzle and the opening in the compaction foot is a conical hole having its larger diameter opening at a side of the compaction foot facing the nozzle and its smaller diameter opening at a side of the compaction foot facing the substrate;
- with the heating element, heating the nozzle to a temperature that permits the flexible filament to be bonded to the substrate;
- with one or more actuators, creating relative vertical motion between the nozzle and the compaction foot to bring the first portion of the flexible filament into contact with the substrate;
- retaining the first portion of the flexible filament in contact with the substrate until the first portion of the flexible filament adheres to the substrate;
- and
- moving the nozzle relative to the substrate with the flexible filament in tension.
Dependencies are inferred from the claim text.