# US 2019/0168451 A1 · Methods for fiber reinforced additive manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0168451 A1 - Document ID: US20190168451A1 - Status: Published application - Kind: A1 - Application number: 16/055,483 - Filed: 2018-08-06 - Published: 2019-06-06 - Earliest claimed: 2013-03-22 - Assignees: Markforged, Inc. - Applicants: Markforged, Inc. - Inventors: Gregory Thomas Mark - Web page: https://patentgrep.com/patent/US20190168451A1 ## CPC - B29C 64/141: using only solid materials - 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 31/042: {using dispensing heads, e.g. extruders, placed over or apart from the moulds (positioning extruded preforms on conveyors B29C31/085)} - B29C 31/044: {with moving heads for distributing liquid or viscous material into the moulds} - B29C 31/045: {moving along predetermined circuits or distributing the material according to predetermined patterns} - B29C 31/048: {the material being severed at the dispensing head exit, e.g. as ring, drop or gob, and transported immediately into the mould, e.g. by gravity} - B29C 48/0022: {combined with cutting} - B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM] - B29C 64/209: Heads; Nozzles - B29C 64/321: Feeding - B29C 69/001: {a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts (for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence)} - B29C 70/16: using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} - B29C 70/382: {Automated fiber placement [AFP]} - B29C 70/521: {and impregnating the reinforcement before the die} - B29C 70/523: {and impregnating the reinforcement in the die} - B29C 70/525: {Component parts, details or accessories; Auxiliary operations} - B29C 70/528: {Heating or cooling} - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 50/02: for controlling or regulating additive manufacturing processes - B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials - B29K 2025/08: {Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene (B29K2055/02 takes precedence)} - B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material - B29K 2071/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material - B29K 2077/00: Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material - B29K 2079/085: {Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof} - B29K 2105/08: of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns - B29L 2031/3085: {Wings} - 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 - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle. ## Claims ### Claim at position 1 -20. (canceled) ### Claim 21 A three-dimensional printer for additive manufacturing of a part, comprising: a build plate configured to support the part; a tray configured to contain a photopolymer resin; a printhead including a nozzle configured to deposit a continuous or semi-continuous core filament within a layer of the photopolymer resin; a motorized feeding mechanism configured to drive the continuous or semi-continuous core filament through the nozzle; a motorized printhead transport mechanism configured to relatively move the printhead and the build plate; a source of electromagnetic radiation configured to generate electromagnetic radiation; a controllable mirror configured to direct the electromagnetic radiation generated by the source of electromagnetic radiation; and a controller operatively connected to the controllable mirror and configured to control the controllable mirror to direct the electromagnetic radiation to a desired location in the layer of photopolymer resin containing the deposited continuous or semi-continuous core filament ### Claim 22 (depends on 21) The three-dimensional printer of claim 21, wherein the tray is further configured to contain the photopolymer resin in a liquid or powder form. ### Claim 23 (depends on 21) The three-dimensional printer of claim 21, wherein the electromagnetic radiation generated by the source of electromagnetic radiation is one of laser and ultraviolet light. ### Claim 24 (depends on 21) The three-dimensional printer of claim 21, further comprising a cutter configured to sever the continuous or semi-continuous core filament. ### Claim 25 (depends on 21) The three-dimensional printer of claim 21, wherein the controller is further configured to control the controllable mirror to direct the electromagnetic radiation from the source of electromagnetic radiation to sever the continuous or semi-continuous core filament. ### Claim 26 (depends on 21) The three-dimensional printer of claim 21, wherein the motorized feeding mechanism is configured to drive the continuous or semi-continuous core filament through the nozzle at a feed rate equal to the deposition rate of the continuous or semi-continuous core filament from the nozzle. ### Claim 27 A method for additive manufacturing of a part, the method comprising: feeding a continuous or semi-continuous core filament into a printhead, wherein the printhead includes a nozzle; lowering a build plate by a layer thickness to allow a new layer of photopolymer resin to form on the build plate; controlling the nozzle to deposit the continuous or semi-continuous core filament within the new layer of photopolymer resin such that photopolymer resin surrounds the deposited continuous or semi-continuous core filament; and curing, during a curing process, the photopolymer resin surrounding the deposited continuous or semi-continuous filament by: generating electromagnetic radiation from a source of electromagnetic radiation; and directing the electromagnetic radiation to the photopolymer resin surrounding the deposited continuous or semi-continuous core filament to harden the photopolymer resin surrounding the deposited continuous or semi-continuous core filament. ### Claim 28 (depends on 27) The method according to claim 27, wherein lowering the build plate by a layer thickness to allow the new layer to form on the build plate includes lowering the build plate by a layer thickness in a tray containing the photopolymer resin in liquid form to allow the new layer of liquid photopolymer resin to form on the build plate. ### Claim 29 (depends on 28) The method according to claim 28, wherein curing the photopolymer resin surrounding the deposited continuous or semi-continuous core filament further comprises allowing the deposited continuous or semi-continuous core filament to be completely submerged within the layer of liquid photopolymer resin. ### Claim 30 (depends on 29) The method according to claim 29, further comprising initiating the curing process after the deposited continuous or semi-continuous core filament is completely submerged within the layer of photopolymer resin. ### Claim 31 (depends on 30) The method according to claim 30, wherein curing the photopolymer resin surrounding the deposited continuous or semi-continuous core filament includes curing the photopolymer resin surrounding the continuous or semi-continuous core filament in a location behind a travel path of the nozzle. ### Claim 32 (depends on 31) The method according to claim 31, further comprising defining a distance between the location behind a travel path of the nozzle and the nozzle to allow for the continuous or semi-continuous core filament to be completely submerged within the layer of photopolymer resin. ### Claim 33 (depends on 27) The method according to claim 27, wherein lowering the build plate by a layer thickness to allow the new layer to form on the build plate includes lowering the build plate by a layer thickness to allow the new layer of photopolymer resin in powder form to be deposited on the build plate. ### Claim 34 (depends on 27) The method according to claim 27, wherein directing the electromagnetic radiation includes controlling a controllable mirror to direct the electromagnetic radiation to a desired location in the layer of photopolymer resin containing the deposited continuous or semi-continuous core filament. ### Claim 35 (depends on 27) The method according to claim 27, further comprising cutting, using a cutter or the electromagnetic radiation used to harden the photopolymer resin, the continuous or semi-continuous core filament. ### Claim 36 (depends on 27) The method according to claim 27, wherein feeding the continuous or semi-continuous core filament into the printhead further comprises feeding the continuous or semi-continuous core filament at a feed rate equal to a deposition rate of the continuous or semi-continuous core filament from the nozzle. ### Claim 37 (depends on 27) The method according to claim 27, further comprising holding the deposited continuous or semi-continuous core filament in place at multiple points within the layer of photopolymer resin as the nozzle continues to deposit the continuous or semi-continuous core filament within the layer of photopolymer resin. ### Claim 38 (depends on 37) The method according to claim 37, wherein holding the deposited continuous or semi-continuous core filament in place at multiple points within the layer of photopolymer resin as the nozzle continues to deposit the continuous or semi-continuous core filament within the layer of photopolymer resin includes directing the electromagnetic radiation to the multiple points within the layer of photopolymer resin to form hardened resin that holds the deposited continuous or semi-continuous core filament in place at the multiple discrete points within the layer of photopolymer resin. ### Claim 39 (depends on 37) The method according to claim 37, wherein controlling the nozzle to deposit the continuous or semi-continuous core filament within the layer of photopolymer resin includes controlling a deposition path of the nozzle such that adjacent portions of the continuous or semi-continuous core filament are deposited within the same layer. ### Claim 40 (depends on 39) The method according to claim 39, further comprising curing the photopolymer resin surrounding the adjacent portions of the continuous or semi-continuous core filament within the same layer of photopolymer resin by directing the electromagnetic radiation in a direction perpendicular to the direction of deposition of the adjacent portions of the continuous or semi-continuous core filament to maximize cross-linking between adjacent portions of the continuous or semi-continuous core filament.