US 2026/0227761 A1 · DATA-DRIVEN ADDITIVE MANUFACTURING

Abstract

The present invention provides a data-driven additive manufacturing (AM)—compression molding (CM) process in which a fiber-reinforced thermoplastic is deposited into a mold cavity and subsequently consolidated under heat and pressure. Deposition and molding parameters are selected using a numerical model to control microstructural characteristics and final part performance. Measured process data is fed to a control system to update the numerical model in real time. The control system is further configured to modify at least one AM or CM parameter based on a deviation between the measured process data and a model-predicted microstructural state. AM process parameters can include material flow rate, print speed, nozzle geometry, nozzle-to-substrate gap height, or material extrusion temperature. CM process parameters can include compression pressure, mold temperature, and compression timing after deposition.

Claims20

Dependent claims

A method of manufacturing a composite article, comprising:

preselecting an additive manufacturing process parameter and a compression molding process parameter according to a hybrid manufacturing process;
depositing a fiber-reinforced thermoplastic material within a mold cavity according to the preselected additive manufacturing process parameter to form a composite preform;
acquiring process measurement data during or after formation of the composite preform, the process measurement data being indicative of an actual state of the composite preform;
comparing the acquired process measurement data with a predicted value associated with fiber orientation or porosity of the composite preform;
modifying, based on the comparison, at least one of the preselected additive manufacturing process parameter or the preselected compression molding process parameter;
and
compression molding the composite preform within the mold cavity under heat and pressure using the modified process parameter to form a consolidated composite article.

4 more elements

Dependencies are inferred from the claim text.

Data-driven additive manufacturing - compression molding

Life of this patent

Data-driven additive manufacturing - compression molding

Life of this patent

Abstract

Claims20