CN109080170B - Manufacturing method of continuous fiber composite material shell - Google Patents

Manufacturing method of continuous fiber composite material shell Download PDF

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Publication number
CN109080170B
CN109080170B CN201811161262.0A CN201811161262A CN109080170B CN 109080170 B CN109080170 B CN 109080170B CN 201811161262 A CN201811161262 A CN 201811161262A CN 109080170 B CN109080170 B CN 109080170B
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resin
continuous fiber
preform
vacuum
manufacturing
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CN109080170A (en
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栾丛丛
傅建中
姚鑫骅
王振威
刘加朋
贺永
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Zhejiang University ZJU
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Zhejiang University ZJU
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/36Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting

Abstract

The invention discloses a method for manufacturing a continuous fiber composite shell, which comprises the following steps: (1) the movement module drives the thermoplastic material extrusion mechanism to print a core mold on the printing platform according to a pre-designed structure, and the core mold is provided with a resin flow channel aligned with the liquid passing hole; (2) the motion module drives the winding mechanism and the printing platform to wind dry continuous fibers on the printed core mold according to a designed path to obtain a prefabricated body; (3) the film laminating mechanism is used for covering a vacuum film on the continuous fiber preform, a resin runner at the lower part of the preform is communicated with the liquid passing hole and the continuous fiber area, a resin runner at the upper part of the preform is communicated with the continuous fiber area, and the top of the preform is provided with a resin flow guide port; (4) pumping the resin liquid into a resin liquid box, starting a vacuum pump of the vacuum auxiliary unit, and gradually uploading the resin liquid from the bottom to the top of the continuous fiber preform; (5) and after the resin is cured, removing the structural part from the printing platform, resetting each module, and finishing the whole working process.

Description

Manufacturing method of continuous fiber composite material shell
Technical Field
The invention relates to the technical field of continuous fiber composite material manufacturing, in particular to a method for manufacturing a continuous fiber composite material shell.
Background
The carbon fiber serving as a strategic material developed by the country has the excellent characteristics of high strength, high rigidity, low specific gravity, friction and wear resistance, recycling and the like, is a new generation of high-performance and light-weight advanced material, and a composite material prepared from the carbon fiber has an important application prospect in the fields of automobiles, ships, aerospace, rail transit, medical appliances and the like. However, the traditional carbon fiber composite material structural member faces the problems of complex manufacturing process, long production period, often required mold and difficulty in realizing complex structure manufacturing. The development of new moulds for the manufacture of single-type small-lot structural components, in particular of single-piece structures, undoubtedly leads to an increase in production cycle times and production costs.
Three-dimensional printing techniques that have emerged in recent years are considered to be one of the most suitable techniques for individualized structure manufacturing. The patent document with the application number of ZL2014103256503 discloses a 3D printer for continuous long fiber reinforced composite materials and a printing method thereof, a mold and a fiber prepreg tape which is processed in advance do not need to be customized in the process, the cost is greatly reduced, meanwhile, the 3D printing method is adopted, the direction of reinforced fibers in manufactured parts is controlled better and more conveniently, composite material parts with customized mechanical properties are obtained more easily, and the rapid manufacturing of composite material parts with complex structures can be realized. For another example, patent document No. CN107127972A discloses a nozzle and a printer for additive manufacturing of continuous fiber reinforced composite material, which comprises an outer nozzle and an inner nozzle, wherein the nozzle has a simple structure and a small size, and can improve the forming precision; in addition, the vertical distance between the outlet of the inner spray head and the outlet of the outer spray head is adjustable, the centering performance of the fiber composite material can be controlled, the molding quality is improved, and the additive manufacturing of the continuous fiber reinforced composite material is realized.
The method and the device mainly solve the problem of how to realize the mixing and printing of the continuous carbon fiber thermoplastic material, but the mechanical property of the continuous fiber composite material in the printing direction is poor due to the process characteristics of the additive manufacturing technology which are overlapped layer by layer; in addition, printed structures are also subject to the properties of the thermoplastic matrix, which are still far from mechanically comparable to structures produced by conventional continuous carbon fiber composite manufacturing processes.
Disclosure of Invention
The invention provides a method for manufacturing a continuous fiber composite shell, which combines a three-dimensional printing technology, a fiber winding technology and a vacuum auxiliary impregnation technology to realize the rapid manufacturing of a high-strength complex continuous fiber composite shell structure.
A method for manufacturing a continuous fiber composite shell, which adopts a continuous fiber composite shell manufacturing device comprising:
a frame;
a motion module mounted on the frame;
the thermoplastic material extruding unit and the wire winding mechanism are driven by the movement module;
a printing platform comprising:
the top surface of the resin liquid tank is open and is driven by the motion module;
the molding supporting plate seals the top surface of the resin liquid tank, a plurality of liquid passing holes are distributed on the surface of the molding supporting plate, and liquid guide pipes extending into the resin liquid tank are connected to the back surfaces of the liquid passing holes;
a dip module, comprising:
a resin supply unit that supplies resin to the resin liquid tank;
the film coating mechanism is used for coating the dried continuous fiber preform;
the vacuum auxiliary unit is used for providing vacuum suction for the resin flow guide port on the continuous fiber preform;
the manufacturing process is as follows:
(1) the movement module drives the thermoplastic material extrusion mechanism to print a core mold on the printing platform according to a pre-designed structure, and the core mold is provided with a resin flow channel aligned with the liquid passing hole;
(2) the motion module drives the winding mechanism and the printing platform to wind dry continuous fibers on the printed core mold according to a designed path to obtain a prefabricated body;
(3) the film laminating mechanism is used for covering a vacuum film on the continuous fiber preform, a resin runner at the lower part of the preform is communicated with the liquid passing hole and the continuous fiber area, a resin runner at the upper part of the preform is communicated with the continuous fiber area, and the top of the preform is provided with a resin flow guide port;
(4) the tail end of a suction pipe of the vacuum auxiliary unit is aligned with a resin flow guide opening arranged on the preform under the control of the motion module, an oil pump of the resin supply unit is started, the resin liquid is pumped into a resin liquid tank, a vacuum pump of the vacuum auxiliary unit is started, the resin liquid is gradually uploaded to the top from the bottom of the continuous fiber preform under the assistance of the vacuum pump, the impregnation of the whole structure is realized, and the vacuum pump and the oil pump of the resin supply unit are closed;
(5) and after the resin is cured, removing the structural part from the printing platform, resetting each module, and finishing the whole working process.
To facilitate removal of the support structure, it is preferred that in step (1) the mandrel is formed from a water-soluble thermoplastic material. Such as polyvinyl alcohol PVAL water-soluble materials, acrylic AA copolymer water-soluble materials and the like. The removal of the support structure can be achieved by placing the entire structure in a solution to directly obtain the final structure.
In order to improve the strength of the structural member, it is preferable that in the step (2), the continuous fibers are wound in a plurality of layers, and the continuous fibers of adjacent layers have included angles therebetween.
For the convenience of manufacturing, the included angle between the continuous fibers of the adjacent layers is not excessively large, and preferably, in the step (2), the included angle is 5-45 degrees.
In order to achieve uniform resin impregnation, it is preferable that in step (1), the resin runners are provided in a plurality and uniformly distributed along the circumferential direction.
In order to ensure the dipping effect and realize the full dipping of the dry continuous fiber preform, it is further preferable that the inner side of the vacuum film is sequentially provided with a flow guide net and a demoulding cloth, and the vacuum film is a special composite film.
In order to cooperate with the method of the invention to ensure that the thermoplastic material extruding unit, the wire winding mechanism and the dipping module do not interfere with each other, preferably, the moving module comprises an XY-axis moving unit arranged above the printing platform, and the XY-axis moving unit is provided with two power output ends for respectively driving the thermoplastic material extruding unit and the wire winding mechanism.
The vacuum auxiliary unit is provided with a lifting mechanism, a vacuum pump and a vacuum hose, and preferably, the vacuum hose of the vacuum auxiliary unit and the thermoplastic material extrusion unit are arranged on the power output end of the same XY axis movement unit.
In order to cooperate with the method of the present invention to rapidly complete the core making and winding, preferably, the motion module comprises:
a Z-axis motion unit;
the mounting frame is fixed on the power output end of the Z-axis motion unit;
the turnover mechanism comprises a turnover motor and a turnover frame, the turnover motor is fixedly arranged on a motor base on the mounting frame, one end of the turnover frame is connected with a turnover motor shaft, and the other end of the turnover frame is rotatably arranged on the mounting frame;
and the rotating motor is arranged on the roll-over stand, and the resin liquid tank is arranged on the rotating shaft.
The structure can drive the structural part to turn and rotate, so that the structural part can be quickly wound.
In order to facilitate the opening and sealing of the resin tank in conjunction with the method of the present invention, it is preferred that the shaped pallet is screw-engaged with the top opening of the resin tank.
In order to be suitable for structural members with different shapes, the liquid passing holes on the forming supporting plate are preferably distributed in an annular shape from inside to outside. The multiple annular arrangements are suitable for impregnating shell structural members with different diameters.
In order to further improve the application range, the diameters of the liquid passing holes on the same ring are preferably different. The liquid passing holes on the same ring can be suitable for soaking shell structural parts with different thicknesses.
In order to realize automatic vacuum film covering, preferably, the film covering mechanism comprises a vacuum film feeding unit and a six-degree-of-freedom manipulator. And the vacuum film is covered on the wound dry continuous fiber preform by means of the mechanical arm and the rotary motion of the printing platform.
The invention has the beneficial effects that:
(1) the manufacturing method of the continuous fiber composite shell combines the three-dimensional printing technology with the continuous fiber winding technology and the vacuum auxiliary impregnation technology, and realizes the rapid manufacturing of the continuous fiber composite shell;
(2) the invention solves the problems that the traditional carbon fiber composite structural member has complex manufacturing process, longer production period, often needs a die and is difficult to realize the manufacture of a complex structure, and simultaneously can overcome the problem that the structural member manufactured by the existing continuous fiber composite three-dimensional printing technology has low strength.
Drawings
FIG. 1 is a schematic flow diagram of a method of manufacturing a continuous fiber composite shell of the present invention.
Fig. 2 is a schematic view showing the overall structure of the continuous fiber composite shell manufacturing apparatus used in the present invention.
Fig. 3 is a schematic structural view of fig. 2 with a portion of the structure removed.
Fig. 4 is a schematic structural diagram of the printing platform in fig. 2.
Fig. 5 is a schematic structural view of a resin tank of the present invention.
FIG. 6 is a schematic structural view of a shaped pallet of the present invention.
Fig. 7 is a schematic illustration of the core making operation of the method of the present invention.
Fig. 8 is a schematic diagram of the winding operation of the method of the present invention.
FIG. 9 is a schematic representation of the impregnation operation of the process of the present invention.
The figures are numbered: 1. a carrying platform, 2, a six-degree-of-freedom mechanical arm, 3, a vacuum pump, 4, a thermoplastic material extrusion unit, 5, a Y-axis movement unit, 6, a vacuum auxiliary unit, 7, a Z-axis movement unit, 8, a winding mechanism, 9, an X-axis movement unit, 10, a resin supply unit, 11, continuous fibers, 12, a prefabricated body, 46, a hanging plate, 101, a printing platform, 102, a mounting frame, 103, a vacuum film feeding unit, 104, a turnover frame, 105, a rotating motor, 106, a turnover motor, 301, a vacuum hose, 401, a thermoplastic material extrusion mechanism, 402, a thermoplastic material supply unit, 403, a thermoplastic material conduit, 601, a vacuum hose guide sleeve, 602, a lifting mechanism, 603, a driving motor, 801, a lifting mechanism, 802, a continuous fiber feeding mechanism, 803, a continuous fiber conduit, 804, a driving motor, 1001, a resin liquid conduit, 1002, a resin liquid tank oil pump, 1003. resin liquid 1011 forming supporting plate 1012 resin liquid box 4011 extruder 4012 printing nozzle 4013 radiating fan 4021 thermoplastic material 4022 thermoplastic material support 10111 external thread 10112 hose 10121 resin liquid box connector 10122 internal thread 10123 resin liquid discharge port.
Detailed Description
As shown in fig. 1 to 9, the continuous fiber composite shell manufacturing apparatus used in the continuous fiber composite shell manufacturing method of the present embodiment includes: the device comprises a carrying platform 1, a six-degree-of-freedom manipulator 2, a vacuum pump 3, a thermoplastic material extrusion unit 4, a Y-axis motion unit 5, a vacuum auxiliary unit 6, a Z-axis motion unit 7, a wire winding mechanism 8 and an X-axis motion unit 9. The X-axis movement unit 9 and the Y-axis movement unit 5 form a translation movement unit, two movement output ends are arranged, one movement output end is provided with the thermoplastic material extrusion unit 4 and the vacuum auxiliary unit 6 through the hanging plate 46, and the vacuum auxiliary unit 6 realizes the up-and-down lifting movement through the upgrading mechanism 602; one is provided with a wire winding mechanism 8 through a lifting mechanism 801, and the wire winding mechanism 8 adopts a wire feeding mechanism 802 to realize functions; the vacuum assist unit 6 is provided with a vacuum hose guide 601.
The stage 1 includes: a printing platform 101, a mounting frame 102, a turnover mechanism and a rotating motor 105. The turnover mechanism comprises a turnover motor 106 and a turnover frame 104, the turnover motor 106 is fixedly mounted on a motor base on the mounting frame 102, one end of the turnover frame 104 is connected with a turnover motor shaft, and one end of the turnover frame is rotatably mounted on the mounting frame 102. The rotating motor 105 is arranged on the roll-over stand 104; the printing platform 101 is mounted on the rotating shaft of the rotating motor 105.
The printing platform 101 includes: a resin liquid tank 1012 mounted on the rotation shaft of the rotary motor 105, and a molding pallet 1011 fixedly connected to the resin liquid tank 1012.
The resin liquid tank is provided with a resin liquid tank connection port 10121 connected to the resin liquid supply unit, an internal thread 10122 for mounting the molding pallet, and a resin liquid discharge port 10123 for discharging the resin liquid.
In order to ensure that the resin quickly impregnates the dried continuous fibers, a plurality of liquid passing holes are annularly distributed from inside to outside on the forming supporting plate, and the liquid passing holes are communicated with the resin in the resin liquid tank 1012 through a hose 10112.
The continuous fiber composite shell manufacturing method of the embodiment comprises the following steps:
each module is reset, the wire feeding mechanism 802 is driven by the lifting mechanism 801 to be lifted to the highest position, and the wire feeding mechanism is driven by a ball screw on the X axis to integrally move to the rightmost side of the X axis; similarly, the guide sleeve 601 of the vacuum hose 301 of the vacuum auxiliary unit 6 moves down to the highest position under the driving of the lifting mechanism 602, and moves to the leftmost side of the X axis together with the thermoplastic material extruding mechanism 401 under the driving of another ball screw of the X axis; the end effector of the six-degree-of-freedom manipulator 2 moves to the leftmost side together with the mechanical arm; disconnecting the impregnation module resin supply unit 10 from the resin tank 1012; the printing platform of the core making module is driven by the Z-axis motion unit 7 to move downwards to the uppermost end;
core making is carried out, and a thermoplastic material extruding mechanism 401 is adopted to print a core mold on the carrying platform 1 according to a pre-designed structure; the specific process is that after thermoplastic material 4021 enters an extruder 4011 through a thermoplastic material conduit 403, a pre-designed core mold is printed on a forming supporting plate 1011 through a printing spray head 4012, and a cooling fan 4013 accelerates the cooling of the molten thermoplastic material. The preset resin flow channel is aligned with the liquid passing hole on the forming support plate 1011, core molds with different structures can be printed on the forming support plate 1011 according to different shapes of the structural member 12, and the preset resin flow channel can be adjusted according to requirements.
And (3) winding, after core mold printing is finished, moving the thermoplastic material extruding mechanism 401 to the leftmost side of the X axis, starting the winding mechanism 8, enabling the continuous fibers 11 to enter the continuous fiber feeding mechanism 802 through the continuous fiber guide pipe 803, and under the driving of the lifting mechanism 801 by the driving motor 804, realizing the winding of the continuous fibers on the pre-printed core mold according to a designed path by combining the rotation and the overturning motion of the forming supporting plate 1011 to obtain a prefabricated body 12, wherein a fiber layer on the prefabricated body 12 is communicated with a resin runner.
Dipping, after the fiber winding is finished, moving the winding mechanism 8 to the rightmost side of the X axis, covering a vacuum film on the continuous fiber preform 12 from the vacuum film feeding unit 103 by the six-degree-of-freedom manipulator 2, and connecting a resin liquid conduit 1001 on a resin liquid tank oil pump 1002 in the resin supply unit 10 with a resin liquid tank 1012 of the printing platform 101; the tail end 601 of the vacuum hose 301 of the vacuum auxiliary unit 6 is aligned with a resin diversion port arranged on the prefabricated body 12 under the control of the lifting mechanism 602 driven by the driving motor 603 and the X-axis movement unit; starting an oil pump 1002 of the resin supply unit 10 to pump the resin liquid 1003 to fill a resin liquid tank 1012; starting a vacuum pump 3 of the vacuum auxiliary unit 6, gradually conveying resin liquid 1003 from a liquid passing hole to a resin flow channel inlet at the bottom of the continuous fiber preform 12 to the top under the assistance of the vacuum pump 3, realizing the impregnation of the whole structure, and closing the vacuum pump 3 and an oil pump 1002 of the resin supply unit 10 to finish the impregnation process;
and (4) curing, after the resin is cured, removing the structural part 12 from the printing platform 101, resetting each module, and finishing the whole working process.
The above description is only for the preferred embodiment of the present invention and is not intended to limit the scope of the present invention, and all equivalent structural changes made by using the contents of the present specification and the drawings can be directly or indirectly applied to other related technical fields and are included in the scope of the present invention.

Claims (6)

1. A method for manufacturing a continuous fiber composite shell is characterized in that the adopted continuous fiber composite shell manufacturing equipment comprises the following steps:
a frame;
the motion module is arranged on the rack;
the thermoplastic material extruding unit and the wire winding mechanism are driven by the movement module;
a printing platform comprising:
the top surface of the resin liquid tank is open and is driven by the motion module;
the molding supporting plate seals the top surface of the resin liquid tank, a plurality of liquid passing holes are distributed on the surface of the molding supporting plate, and liquid guide pipes extending into the resin liquid tank are connected to the back surfaces of the liquid passing holes;
a dip module, comprising:
a resin supply unit that supplies resin to the resin liquid tank;
the film coating mechanism is used for coating the dried continuous fiber preform;
the vacuum auxiliary unit is used for providing vacuum suction for the resin flow guide port on the continuous fiber preform;
the manufacturing process is as follows:
(1) the movement module drives the thermoplastic material extrusion mechanism to print a core mold on the printing platform according to a pre-designed structure, and the core mold is provided with a resin flow channel aligned with the liquid passing hole;
(2) the motion module drives the winding mechanism and the printing platform to wind dry continuous fibers on the printed core mold according to a designed path to obtain a prefabricated body;
(3) the film laminating mechanism is used for covering a vacuum film on the continuous fiber preform, a resin runner at the lower part of the preform is communicated with the liquid passing hole and the continuous fiber area, a resin runner at the upper part of the preform is communicated with the continuous fiber area, and the top of the preform is provided with a resin flow guide port;
(4) the tail end of a suction pipe of the vacuum auxiliary unit is aligned with a resin flow guide opening arranged on the preform under the control of the motion module, an oil pump of the resin supply unit is started, the resin liquid is pumped into a resin liquid tank, a vacuum pump of the vacuum auxiliary unit is started, the resin liquid is gradually uploaded to the top from the bottom of the continuous fiber preform under the assistance of the vacuum pump, the impregnation of the whole structure is realized, and the vacuum pump and the oil pump of the resin supply unit are closed;
(5) and after the resin is cured, removing the structural part from the printing platform, resetting each module, and finishing the whole working process.
2. The method of manufacturing a continuous fiber composite shell according to claim 1, wherein in step (1), the core mold is made of a water-soluble thermoplastic material.
3. The method of manufacturing a continuous fiber composite shell according to claim 1, wherein in step (2), the continuous fibers are wound in a plurality of layers, and the continuous fibers of adjacent layers have included angles therebetween.
4. The method of claim 3, wherein in step (2), the included angle is between 5 ° and 45 °.
5. The method for manufacturing a continuous fiber composite casing according to claim 1, wherein in the step (1), the resin runners are provided in plural numbers and uniformly distributed along the circumferential direction.
6. The method for manufacturing a continuous fiber composite shell according to claim 1, wherein in the step (3), a flow guide net and a release cloth are sequentially arranged on the inner side of the vacuum film.
CN201811161262.0A 2018-09-30 2018-09-30 Manufacturing method of continuous fiber composite material shell Active CN109080170B (en)

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Publication number Priority date Publication date Assignee Title
CN105773975A (en) * 2016-04-19 2016-07-20 浙江大学 Method and device for inlaying pre-tensioned carbon fiber based on three-dimensional printing
CN106853694A (en) * 2017-02-21 2017-06-16 江苏恒神股份有限公司 The preparation method of the SQRTM moulding process carbon fiber grilles based on water-soluble core
CN107839225A (en) * 2017-10-31 2018-03-27 陕西斐帛科技发展有限公司 A kind of Screw Extrusion continuous fiber composite material 3D printing device and method
CN108327265A (en) * 2018-02-09 2018-07-27 合肥工业大学 A kind of desktop type automatic carbon fiber winding forming machine
CN108472884A (en) * 2015-12-22 2018-08-31 阿博格有限公司 Device and method for manufacturing three-dimension object using fiber transporting device

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2017132142A (en) * 2016-01-28 2017-08-03 株式会社リコー Material for three-dimensional molding, material set for three-dimensional molding and manufacturing method of three-dimensional molding
DE102016002623B4 (en) * 2016-03-07 2017-09-28 Premium Aerotec Gmbh Method and device for producing components with defined dimensions

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108472884A (en) * 2015-12-22 2018-08-31 阿博格有限公司 Device and method for manufacturing three-dimension object using fiber transporting device
CN105773975A (en) * 2016-04-19 2016-07-20 浙江大学 Method and device for inlaying pre-tensioned carbon fiber based on three-dimensional printing
CN106853694A (en) * 2017-02-21 2017-06-16 江苏恒神股份有限公司 The preparation method of the SQRTM moulding process carbon fiber grilles based on water-soluble core
CN107839225A (en) * 2017-10-31 2018-03-27 陕西斐帛科技发展有限公司 A kind of Screw Extrusion continuous fiber composite material 3D printing device and method
CN108327265A (en) * 2018-02-09 2018-07-27 合肥工业大学 A kind of desktop type automatic carbon fiber winding forming machine

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