Systems and methods relating to 3D printing composite structures
AssigneeDesktop Metal, Inc.
InventorKonstantinos A. Fetfatsidis
Life of this patent
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Abstract
In part, the disclosure relates to systems and methods of layer-by-layer assembly of composite structures such as for parts or workpieces. Various additive and subtractive processes can be used. In various embodiments, prepreg tapes that include continuous reinforcing fibers are used. In one aspect, a system that includes printer heads is provided. The printer heads may, in some embodiments, be used for manufacturing high quality continuous fiber reinforced structural parts. In some embodiments, the system includes a first printer head configured to lay down tape (e.g., a thermoplastic tape that includes reinforcing fibers).
Claims13
A method of manufacturing a part comprising:
- printing a three-dimensional support, using a fused filament fabrication-based print head, wherein the support comprises layers of fused polymer filament;
- heating one or more segments of prepreg thermoplastic tape, using a heating element disposed in a tape deposition head;
- depositing one or more heated segments of prepreg thermoplastic tape on the three-dimensional support in one or more directions;
- cooling a compaction roller of the tape deposition head using a fan to direct air having a first temperature relative to a surface of the compaction roller such that temperature of the compaction roller decreases;
- directing heated air from the compaction roller having a second temperature to one or more heating elements disposed in the tape deposition head, wherein second temperature is higher than first temperature;
- compacting, the one or more segments of prepreg thermoplastic tape such that the one or more segments conform to the support;
- and
- repeating depositing and compacting steps and periodically changing the one or more directions until a fiber-reinforced multi-layer part comprising one or more surfaces is formed, wherein at least one surface of the one or more surfaces is defined by the support.
Dependencies are inferred from the claim text.