Method and apparatus for continuous composite three-dimensional printing
AssigneeContinuous Composites Inc.
InventorKenneth Lyle Tyler
Life of this patent
Estimating the term…
Abstract
A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.
Claims64
A continuous-composite printing apparatus for manufacturing an object, the apparatus comprising:
- a platform;
- a positioning system;
- a providing device that provides a fiber strand pre-pregged with polymer;
- a supply device that provides a supply of polymer;
- a mount;
- an extruder connected to the positioning system via the mount, the extruder including:
- a head configured to receive the pre-pregged fiber strand from the providing device;
- and
- a dispensing port located at an outlet end of the head and configured to dispense the pre-pregged fiber strand onto at least one of the platform and the object;
- a heater configured to heat the pre-pregged fiber strand within the extruder;
- a computer system including a processor operatively coupled to the platform, the positioning system, and the extruder, the computer system configured to:
- control the extruder to press the heated pre-pregged fiber strand through the dispensing port and onto at least one of the platform and the object, to form the object;
- control movement of at least one of the positioning system and the platform to position a portion of the heated pre-pregged fiber strand on at least one of the platform and the object;
- and
- control movement of at least one of the positioning system and the platform to pull the positioned portion of the pre-pregged fiber strand such that the pre-pregged fiber strand is pulled through the dispensing port and onto at least one of the platform and the object, to form the object;
- and
- a hardening device that hardens the pre-pregged fiber strand to form the object.
A continuous-composite printing method for manufacturing an object, the method comprising:
- providing, with a providing device, a fiber strand pre-pregged with polymer to a head of an extruder;
- providing, with a supply device, a supply of polymer;
- dispensing the pre-pregged fiber strand through a dispensing port located at an outlet end of the head and onto at least one of a platform and the object;
- heating the pre-pregged fiber strand within the extruder;
- controlling the extruder, using a computer system having a processor, to press the heated pre-pregged fiber strand through the dispensing port and onto at least one of the platform and the object, to form the object;
- controlling movement of at least one of a positioning system to which the extruder is mounted and the platform, using the computer system, to position a portion of the heated pre-pregged fiber strand on at least one of the platform and the object;
- controlling movement of at least one of the positioning system and the platform, by the computer system, to pull the positioned portion of the pre-pregged fiber strand such that the pre-pregged fiber strand is pulled through the dispensing port and onto at least one of the platform and the object, to form the object;
- and
- hardening the pre-pregged fiber strand, using a hardening device, to form the object.
Dependencies are inferred from the claim text.