Large-Scale Continuous Fiber Additive Manufactured-Compression Molded Composite

Invention Reference Number

202104975

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This technology combines 3D printing and compression molding to produce high-strength, low-porosity composite articles. By feeding continuous fiber and polymeric material into an extruder, forming a preform through additive manufacturing, and then compression molding it, the method creates robust parts suitable for industries like automotive, aerospace, and construction.

Description

Additive manufacturing (AM), or 3D printing, enables the creation of complex designs with minimal material waste. However, traditional 3D-printed parts often have poor mechanical properties due to high porosity and weak interlayer bonding. Compression molding (CM) offers high-quality surface finishes and structural integrity but lacks the design flexibility and material efficiency of AM.

The method involves:

Material feeding: Continuous fiber and polymeric material are fed into an extruder with a nozzle.
Preform formation: The materials are extruded to create a three-dimensional preform on a deposition surface. This can involve varying the continuous fiber's volume fraction between 0% and 60%.
Mold preparation: The preform is placed into a mold with top and bottom components.
Compression molding: The preform is compressed under heat and pressure to form a finished article with enhanced mechanical properties.

The method supports a range of polymeric materials (e.g., nylon, PEEK, ABS) and fibers (e.g., carbon, glass, Kevlar) and can produce multi-layered or graded material compositions.

Benefits

Enhanced mechanical properties: Improved flexural strength, tensile modulus, and reduced porosity.
Material efficiency: Minimal waste with complex geometric designs.
Versatile material use: Compatible with various polymers and fibers.
Rapid production: Combines the speed of 3D printing with the robustness of compression molding.

Applications and Industries

Automotive: Lightweight, high-strength components.
Aerospace: Parts requiring complex geometries and high mechanical performance.
Construction: Durable structural elements with optimized properties.
Consumer goods: Strong, durable products with intricate designs