In-line polymerization for customizable composite fiber manufacture in additive manufacturing
AssigneeUniversity of South Carolina
InventorsWout De Backer, Valerie Kay, Michael Van Tooren
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Abstract
A composite fiber for use in additive manufacturing such as fused filament fabrication is described along with methods of its construction and use. The composite fiber includes a single continuous fiber (e.g., a continuous carbon roving) and a polymer (e.g., a high glass transition polymer) in intimate contact. The composite fiber is formed through immersion of the continuous fiber in a series of two or more solutions that together include monomer(s), catalysts, or other materials for generating the polymer as the continuous fiber moves through the solutions.
Claims23
A method for forming a composite fiber for an additive manufacturing device, the method comprising:
- generating an infiltrated fiber by immersing a first region of a continuous fiber in a first solution included in a series of two or more solutions each provided with a respective roller directing movement of the continuous fiber in or past the solutions, wherein the first solution comprises a first monomer, a first catalyst, or both;
- immersing the infiltrated fiber in a second solution included in the series of two or more solutions to generate a first polymer in and/or on the first region of the continuous fiber, wherein the first polymer incorporates the first monomer, and wherein the second solution comprises a second monomer, a second catalyst, or both;
- adjusting a position of the rollers to immerse a second region of the continuous fiber in a third solution included in the series of two or more solutions, wherein at least a portion of the second region is different from the first region and at least a portion of the first region is not immersed in the third solution;
- washing at least the first region of the continuous fiber with a solvent to produce a wet composite fiber;
- and
- removing the solvent from the wet composite fiber.
A system for printing a three-dimensional object, the system comprising:
- a print head configured to receive a composite fiber;
- an infiltration system for generating the composite fiber from a continuous fiber;
- and
- a print bed comprising a printing surface onto which the composite fiber may be selectively applied by the print head to form a work piece,
- wherein the infiltration system comprises a series of two or more solution baths each provided with a respective roller directing movement of the continuous fiber in or past the solution baths, wherein a position of the rollers is configured to be adjusted to immerse first and second regions of the continuous fiber in the solution baths such that at least a portion of the second region is different from the first region and such that at least a portion of the first region is not immersed in a respective one of the solution baths into which the second region is immersed.
Dependencies are inferred from the claim text.