# US 11,897,194 B2 · Method and system for dynamic capillary-driven additive manufacturing of continuous fiber composite > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,897,194 B2 - Document ID: US11897194B2 - Status: Granted - Kind: B2 - Application number: 17/404,365 - Filed: 2021-08-17 - Published: 2022-02-17 - Granted: 2024-02-13 - Earliest claimed: 2020-08-17 - Assignees: University of Delaware - Applicants: Kelvin Fu; Baohui Shi - Inventors: Kelvin Fu; Baohui Shi - Web page: https://patentgrep.com/patent/US11897194B2 ## CPC - 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 70/38: Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} - B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM] - B29C 64/295: Heating elements - B29C 64/321: Feeding - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling - B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials - B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material - B29K 2307/04: Carbon - 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 - 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 A process for additive manufacturing of a thermoset resin fiber reinforced composite comprises depositing a fiber material along a path having a direction; heating the fiber material using a heater to generate a moving thermal gradient in the fiber material trailing the heater relative to the path direction; and dispensing a thermosetting polymer material on the heated fiber material at a trailing distance the from the heater along the path. The thermosetting polymer dynamically wicks into the fiber material along the thermal gradient in the path direction. ## Claims ### Claim 1 A process for additive manufacturing of a thermoset resin fiber reinforced composite, comprising the sequential steps of: depositing a first layer of fiber material along a path having a direction; then, heating the first layer of fiber material using a heater to generate a moving thermal gradient in the first layer of fiber material trailing the heater relative to the path direction; and then, dispensing a thermosetting polymer material on the first layer of heated fiber material at a trailing distance the from the heater along the path; wherein the thermosetting polymer dynamically wicks into the first layer of fiber material along the thermal gradient in the path direction. ### Claim 2 (depends on 1) The process of claim 1, wherein the first layer of fiber material comprises one or more continuous carbon fibers, a carbon-containing material, or one or more non-carbon fibers coated with a carbon-containing material. ### Claim 3 (depends on 2) The process of claim 2, wherein the thermosetting polymer comprises an epoxy. ### Claim 4 (depends on 3) The process of claim 3, wherein the epoxy comprises two-part system comprising a resin and a curing agent, and the method comprises mixing the resin and the curing agent prior to dispensing the material on the heated first layer of fiber material. ### Claim 5 (depends on 1) The process according to claim 1, wherein the first layer of fiber material comprises a plurality of fibers defining one or more spaces between neighboring fibers and the thermosetting polymer wicks into the one or more spaces and surrounds the plurality of fibers. ### Claim 6 (depends on 1) The process according to claim 1, wherein the first layer of fiber material comprises one or more porous fibers having a plurality of pores and the thermosetting polymer wicks into the one or more pores. ### Claim 7 (depends on 1) The process according to claim 1, wherein the thermosetting polymer has a viscosity that decreases with increasing temperature along the thermal gradient. ### Claim 8 (depends on 1) The process according to claim 1, comprising placing the heater in contact with the first layer of fiber material during the step of heating the fiber material. ### Claim 9 (depends on 1) The process according to claim 1, wherein the path is defined on a 2D or 3D substrate or in free space. ### Claim 10 (depends on 1) The process of claim 1, comprising depositing a plurality of layers one on top of another to form the composite. ### Claim 11 (depends on 1) The process according to claim 1, comprising performing the process using a printing head attached to an automated robot arm having at least three degrees of freedom, wherein the printing head includes a source of the fiber material, a guide for disposing the first layer of fiber material in a desired location, the heater spaced a trailing distance from the guide relative to the path direction, and a dispenser for dispensing the thermosetting polymer material at a trailing distance from the heater. ### Claim 12 (depends on 1) The process of claim 1, wherein the trailing distance from the heater at which the thermosetting polymer material is dispensed on the heated first layer of fiber material is within an effective wicking and curing zone of the heated fiber material defined along a continuous portion of the first layer of fiber material. ### Claim 13 (depends on 1) The process of claim 1, wherein thermal gradient defines an increasing temperature along a continuous portion of the first layer of fiber material that defines the trailing distance, the thermal gradient characterized by a first temperature at a location where the thermosetting polymer material is dispensed on the heated first layer of fiber material and a second temperature at a location closest to the heater, wherein the second temperature is greater than the first temperature.