Additive manufacturing using continuous-fiber reinforced composites with graphene

A method for forming a three-dimensional, continuous-fiber reinforced composite part comprising:

• forming a laminate structure comprising a first layer of continuous-fiber reinforced sheet welded to at least one other layer of continuous-fiber reinforced sheet, wherein each of the layers of continuous-fiber reinforced sheets having two opposed faces and comprising a fiber and epoxy resin material composite and graphene or a graphene derivative,
• wherein the welding of the first layer of continuous-fiber reinforced sheet to the at least one other layer of continuous-fiber reinforced sheet comprises causing the epoxy resin material of a first face of the first layer of continuous-fiber reinforced sheet to heat and intermix with the epoxy resin material of a first face of each of the at least one other continuous-fiber reinforced sheets so as to form an interlayer bond between the first layer of continuous-fiber reinforced sheet and the at least one other layer of continuous-fiber reinforced sheet that occupies at least a majority of the first face of the first layer of continuous-fiber reinforced sheet thereby forming the laminate structure and wherein the welding forms an interstitial space between the second face of the first continuous-fiber reinforced sheet and the first face of the second continuous-fiber reinforced sheet, wherein the interstitial space comprises a portion of the resin material and a portion of the graphene or graphene derivative from each of the at least first and second continuous-fiber reinforced sheets.

A method for forming a three-dimensional, continuous-fiber reinforced composite part comprising:

• providing at least first and second continuous-fiber reinforced sheets wherein each of the continuous-fiber reinforced sheets has first and second opposed faces and wherein each of the continuous-fiber reinforced sheets further comprise a fiber and resin material composite and graphene or a graphene derivative;
• placing the first sheet on top of the second sheet so that the second face of the first sheet abuts the first face of the second sheet;
• and
• applying a laser beam to the first face of the first sheet to create a weld between the second face of the first sheet first and the first face of the second sheet thereby forming a laminate structure wherein the weld comprises an interstitial space between the second face of the first continuous-fiber reinforced sheet and the first face of the second continuous-fiber reinforced sheet, wherein the interstitial space comprises a portion of the resin material and a portion of the graphene or graphene derivative
• from each of the at least first and second continuous-fiber reinforced sheets.