# US 2021/0276244 A1 · Corrugated three dimensional (3d) additive manufacturing

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- Number: US 2021/0276244 A1
- Document ID: US20210276244A1
- Status: Published application
- Kind: A1
- Application number: 16/319,677
- Filed: 2017-07-06
- Published: 2021-09-09
- Earliest claimed: 2016-07-22
- Assignees: Virginia Tech Intellectual Properties, Inc.
- Inventors: BROOK KENNEDY; EDWARD OLIN COE
- Web page: https://patentgrep.com/patent/US20210276244A1

## CPC

- B31D 5/00: Multiple-step processes for making three-dimensional [3D] articles
- B22F 10/18: by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
- B23K 10/027: {Welding for purposes other than joining, e.g. build-up welding}
- B23K 15/0086: {welding for purposes other than joining, e.g. build-up welding}
- B23K 15/0093: {characterised by the properties of the materials to be welded}
- B23K 26/0006: {taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence)}
- B23K 26/342: Build-up welding
- B29C 53/22: Corrugating
- B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM]
- B32B 1/00: Layered products having a non-planar shape
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B22F 7/02: of composite layers {(B22F7/002 takes precedence)}
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B23K 2103/02: Iron or ferrous alloys
- B23K 2103/08: Non-ferrous metals or alloys
- B23K 2103/42: {Plastics other than composite materials}
- B23K 2103/50: {Inorganic materials other than metals or composite materials}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- Y02P 10/25: Process efficiency
- B31D: MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C (manufacture by dry processes of articles made from particles or fibres consisting of wood or other lignocellulosic or like organic material B27N; making layered products not composed wholly of paper or cardboard B32B; making articles from cellulosic fibrous suspensions, e.g. wood pulp, D21J)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

In some aspects, described herein are methods of additive manufacturing in which one or more corrugated layers are incorporated into the three-dimensional (3D) object. Also provided herein are 3D objects that can include one or more corrugated layers.

## Claims

### Claim 1

A method of additive manufacturing, the method comprising:
forming a corrugated layer of material using a three-dimensional (3D) printer, wherein the corrugated layer has a thickness, a length, a width, and a height,
wherein the corrugated layer has a cross-sectional area defined by the thickness and width at any given point along the length of the corrugated layer, and
wherein the corrugated layer varies in height along the length of the corrugated layer, and wherein the height of the corrugated layer at a position along the length of the corrugated layer is greater than the height of a planar layer that can be formed using the 3D printer having the same thickness and width as the corrugated layer.

### Claim 2 (depends on 1)

The method of claim 1,
wherein the cross-sectional area of the corrugated layer is substantially constant along the length of the corrugated layer.

### Claim 3 (depends on 1)

The method of claim 1, wherein the cross-sectional area of the corrugated layer varies along the length of the corrugated layer.

### Claim 4 (depends on 1)

The method of claim 1, wherein the height of the corrugated layer is measured along the build direction of the 3D printer.

### Claim 5 (depends on 1)

The method of claim 1, further comprising forming a first transition layer of material using the 3D printer, wherein the first transition layer has a thickness, a length, a width, and a height,
wherein the first transition layer of material has a cross-sectional area defined by the thickness and the width of the first transition layer at any given point along the length of the first transition layer,
wherein the height of the first transition layer varies along the length of the first transition layer,
wherein the height of the first transition layer at a position along the length of the first transition layer is greater than the height of a planar layer that can be formed using the 3D printer having the same thickness and width as the first transition layer, and
wherein the height of the first transition layer is less than the height of the corrugated layer when measured at the same position along the length of the first transition layer and the corrugated layer.

### Claim 6 (depends on 5)

The method of claim 5, wherein the first transition layer is adjacent to the corrugated layer.

### Claim 7 (depends on 5)

The method of claim 5, further comprising the step of forming a second transition layer using the 3D printer, wherein the second transition layer has a thickness, a length, a width, and a height,
wherein the second transition layer of material has a cross-sectional area defined by the thickness and the width of the second transition layer at any given point along the length of the second transition layer,
wherein the height of the second transition layer varies along the length of the second transition layer,
wherein the height of the second transition layer at a position along the length of the second transition layer is greater than the height of a planar layer that can be formed using the 3D printer having the same thickness and width as the second transition layer,
wherein the height of the second transition layer is less than the height of the corrugated layer when measured at the same position along the length of the first transition layer and the corrugated layer, and
wherein the height of the second transition layer is greater than the height of the first transition layer when measured at the same position along the length of the second transition layer and the first transition layer.

### Claim 8 (depends on 7)

The method of claim 7, wherein the first transition layer is adjacent to the second transition layer.

### Claim 9 (depends on 7)

The method of claim 7, wherein the second transition layer is adjacent to the corrugated layer.

### Claim 10 (depends on 5)

The method of claim 5, wherein the step of forming the first transition layer comprises depositing material on a corrugation form,
wherein the corrugation form has a height, length, width, and thickness,
wherein the corrugation form has a cross-sectional area defined by the width and thickness of the corrugation form,
wherein the corrugation form varies in height along the length of the corrugation form, and wherein the variation in height along the length of the corrugation form is substantially the same as the variation in height along the length of the first transition layer.

### Claim 11 (depends on 5)

The method of claim 5, wherein the cross-sectional area of the first transition layer is substantially constant along the length of the first transition layer.

### Claim 12 (depends on 5)

The method of claim 5, wherein the cross-sectional area of the first transition layer varies along the length of the first transition layer.

### Claim 13 (depends on 5)

The method of claim 5, wherein the cross-sectional area of the second transition layer is substantially constant along the length of the second transition layer.

### Claim 14 (depends on 5)

The method of claim 5, wherein the cross-sectional area of the second transition layer varies along the length of the second transition layer.

### Claim 15 (depends on 5)

The method of claim 5, wherein the first transition layer is comprised of planar layers.

### Claim 16 (depends on 5)

The method of claim 5, wherein the second transition layer is comprised of planar layers.

### Claim 17 (depends on 10)

The method of claim 10, wherein the corrugation form is comprised of planar layers.

### Claim 18 (depends on 10)

The method of claim 10, wherein the corrugation form is a non-laminate material.

### Claim 19 (depends on 1)

The method of claim 1, wherein the method of additive manufacturing is fused filament fabrication.

### Claim 20

A three-dimensional laminate object having a corrugated layer produced via an additive manufacturing process comprising:
forming a corrugated layer of material using a three-dimensional (3D) printer, wherein the corrugated layer has a thickness, a length, a width, and a height,
wherein the corrugated layer has a cross-sectional area defined by the thickness and width at any given point along the length of the corrugated layer, and
wherein the corrugated layer varies in height along the length of the corrugated layer, and wherein the height of the corrugated layer at least at one position along the length of the corrugated layer is greater than the height of a planar layer that can be formed using the 3D printer having the same thickness and width as the corrugated layer.

### Claim at position 21

-42. (canceled)