EP3810386A1 - 3d printing device and 3d printing method with continuous extrusion-based fibre additive - Google Patents
3d printing device and 3d printing method with continuous extrusion-based fibre additiveInfo
- Publication number
- EP3810386A1 EP3810386A1 EP19743065.5A EP19743065A EP3810386A1 EP 3810386 A1 EP3810386 A1 EP 3810386A1 EP 19743065 A EP19743065 A EP 19743065A EP 3810386 A1 EP3810386 A1 EP 3810386A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibre
- feed system
- extrusion
- outlet
- base polymer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
- B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C64/00—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
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C64/00—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
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/205—Means for applying layers
- B29C64/209—Heads; Nozzles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C64/00—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
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/56—Tensioning reinforcements before or during shaping
Definitions
- the present invention relates to a device for continuous extrusion- based fibre additive manufacturing.
- the present invention further relates to a method for continuous extrusion-based fibre additive manufacturing and to the use of a product obtained by such method.
- Additive manufacturing is a technology used to efficiently manufacture three-dimensional parts layer-by-layer. Unlike subtractive technologies that require additional time and energy to remove excess material, additive manufacturing deposits material only where it is needed, making very efficient use of both energy and raw materials. Additive manufacturing may be accomplished using polymers, alloys, resins or similar feed stock materials that transition from a liquid or powder to a cured, solid component. In order to construct features such as cantilevered beams, overhangs or arches, sacrificial supports must typically be deposited to counteract the force of gravity. Once the part is complete, the support structures are removed using various mechanical and chemical means. The creation and removal of support structures wastes material and energy and adds time to the build.
- discontinuous or chopped fibre reinforced feed stock enabling“out of the oven” additive manufacturing capability.
- the chopped fibres significantly increase the thermal conductivity and reduce the coefficient of thermal expansion of the material. This allows extremely large parts to be built at room temperature and with significantly less distortion than non-reinforced materials.
- building parts of discontinuous fibre reinforced feed stock provides significant advantages in terms of room temperature processing and dimensional stability, the discontinuous fibres are limited in terms of strength and still require a sacrificial structure for supporting cantilevered or arched features.
- the present invention now provides a device for continuous extrusion-based fibre additive manufacturing, comprising an extrusion chamber comprising at least one base polymer material inlet for feeding a base polymer material to the chamber and an extrusion outlet for extruding the base polymer material from the extrusion chamber, and a fibre feed system, the fibre feed system comprises at least one fibre inlet for feeding a fibre material to the fibre feed system and a fibre outlet for discharging the fibre material from the fibre feed system.
- the fibre feed system is connected to a vacuum unit for applying a vacuum to the fibre feed system.
- a vacuum to the fibre feed system, the base polymer material extruded from the extrusion outlet adheres in an improved manner to the fibre material extruded from the fibre outlet of the fibre feed system resulting in a continuous fibre additive having a further increased strength and stiffness compared to the continuous fibre additives known in the art. It was noted that the formation of air bubbles between the fibre material and the base polymer material is further reduced by applying a vacuum to the fibre feed system.
- the vacuum applied to the fibre feed system extends from the vacuum unit in the direction of the fibre outlet of the fibre feed system.
- the inner diameter of the fibre feed system is chosen such that the diameter is larger than the maximum outer diameter of the fibre material fed to the fibre feed system. In such configuration, the vacuum path extending from the vacuum unit to the fibre outlet of the fibre feed system is kept free from obstacles caused by the fibre material.
- the fibre feed system may further comprise drive means for driving the fibre material through the fibre feed system.
- the drive means of a fibre feed system comprises two cooperating rotating drives.
- other kinds of drive means may be used to move the fibre material through the fibre feed system.
- the at least one base polymer material inlet may be connected to a base polymer feeding system, such as an extruder.
- a base polymer feeding system such as an extruder.
- the base polymer feeding system may be configured to heat the granules of the base polymer material in order to provide an extrudable base polymer material.
- the device is, for example, capable of producing about 25 kilograms of continuous fibre additive per hour. It was further found that by providing the device of the present invention, the device is capable of producing continuous fibre additive 24 hours a day, with a minimum of disruptions due to, for example, clogging of the outlets of the extrusion chamber and fibre feed system. It was further found that by providing the device of the present invention, the device may be used for industrial application, i.e. in printing industrial-sized parts, e.g. boat parts as large as about 4 metres by 2 metres by 1 ,5 metres. It is noted that other sized parts may be produced as well by using the device of the present invention.
- the fibre feed system may be configured to traverse the extrusion chamber wherein the fibre outlet of the fibre feed system coincides with the extrusion outlet of the extrusion chamber.
- the central axis of the extrusion outlet of the extrusion chamber coincides with the central axis of the fibre outlet of the fibre feed system.
- the fibre outlet of the fibre feed system debouches in or extends from the extrusion outlet. It was found that by providing a combined extrusion outlet, i.e. combining the extrusion outlet with the outlet of the fibre feed system, the device of the present invention provides in a robust and reliable way to continuous fibre additive manufacturing.
- a device wherein the extrusion outlet and fibre outlet are positioned such that the continuous fibre additive is formed after the base polymer material is extruded from the extrusion outlet of the extrusion chamber.
- the device facilitates the continuous fibre additive manufacturing.
- the fibre outlet of the fibre feed system may slightly extend from the extrusion outlet.
- the present invention further relates to a method for continuous extrusion-based fibre additive manufacturing, the method comprises the steps of: a) providing a fibre material and a base polymer material;
- the method comprises the step of applying a vacuum to the fibre feed system.
- a vacuum to the fibre feed system, a continuous fibre additive can be produced having further improved strength and stiffness properties.
- the improved product characteristics may be a result of the improved adherence of the base polymer material to the fibre material and/or the reduction in the formation of any air bubbles between the base polymer material and the fibre material.
- the vacuum is applied to the fibre feed system during performance of all the steps of the method of the present invention.
- the extruded continuous fibre additive is formed after the base polymer material is extruded from the extrusion outlet of the extrusion chamber.
- the continuous fibre additive downstream the extrusion outlet of the extrusion chamber, clogging of the extrusion outlet is herewith prevented.
- the method provides an increase of amount of continuous fibre additive manufacturing up to an amount of 25 kilograms per hour. Even further, due to the decreased occurrence of maintenance problems, e.g. clogging of the extrusion outlet, the method of the present invention may be applied for the full 24 hours a day.
- the method of the present invention comprises step b) wherein the base polymer material fed to the extrusion chamber is allowed to enclose the fibre feed system provided with the fibre material.
- the present invention further relates to the use of a continuous fibre additive obtained by the method of the present invention, wherein the method comprises applying a vacuum to the fibre feed system.
- the fibre material suitable for use in the present invention may include continuous fibre reinforcements that are uncut, which provide a considerable strength advantage over chopped fibres.
- Such fibre material may comprise of a tow or bundle of unidirectional, multidirectional or woven filaments and may be round-shaped, ribbon-shaped, or otherwise shaped.
- the filaments may be made from carbon, glass, aramid or other materials having diameters of approximately 5 to 10 micrometres. Depending on the size and strength requirements of the final part, filament counts can be approximately 2,000-50,000, although lower or higher counts and/or varying diameters may also be used.
- the fibre material may comprise dry tows, i.e. filaments wherein no additional material is present.
- the fibre material comprises impregnated fibre materials, i.e.
- the fibre material may comprise a metal wire (e.g. a wire rope) or may comprise glass fibre.
- a glass fibre as fibre material is preferred in order to provide further (sensing) technology into the fibre additive.
- the advantageous properties of glass fibre may be used to transport data/information through the fibre additive.
- the base polymer material suitable for use in the present invention may include a reinforcing polymer material.
- a reinforcing polymer material may be selected from the group consisting of a thermoplastic polymer, a thermoset polymer and a combination thereof.
- Exemplary thermoplastic materials are: ABS, Polycarbonate, PLA, ULTEMTM brand Resin, Polyetherimide (PEI), NYLON and PPSE/PPSU for example. These thermoplastic polymer examples may be combined together or combined with thermoset polymers.
- Exemplary thermoset materials are: Bis-Maleimid (BMI), Epoxy (Epoxide), Phenolic (PF), Polyester (UP), Polyimide, Polyurethane (PUR) and Silicone for example. These thermoset polymers may be combined together or combined with thermoplastic polymers. It is noted that any kind of thermoplastic polymer may be used, i.e. low temperature to high temperature thermoplastic polymers.
- Figure 1 shows a schematically represented part of the device of the present invention.
- Figure 1 shows device 1 suitable for continuous fibre additive 2 manufacturing.
- Device 1 comprises extrusion chamber 3 comprising extrusion inlet 4 and extrusion outlet 5 for feeding to and discharging from extrusion chamber 3 base polymer material 6.
- Device 1 further comprises fibre feed system 7 for feeding fibre material 8 to fibre outlet 9 of fibre feed system 7.
- Fibre feed system 7 is positioned in extrusion chamber 3 such that base polymer material 6 is able to enclose fibre feed system 7 and such that fibre outlet 9 coincides with extrusion outlet 5.
- the fibre outlet 9 may slightly extend from extrusion outlet 5.
- vacuum unit 10 connected to fibre feed system 7.
- Vacuum unit 10 is configured to apply a vacuum on fibre feed system 7 such that the formation of air bubbles at fibre outlet 9 is prevented. Further, by applying a vacuum the adherence of base polymer material 6 to fibre material 8 is further improved.
- Figure 1 further shown drive means 11 in the form of two cooperating wheels and extruder 12 for extruding base polymer material 6 to extrusion chamber 3.
- the device 1 may be installed in a print head (not shown) which is moveable in the X-Y-Z directions.
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NL2021152A NL2021152B1 (en) | 2018-06-19 | 2018-06-19 | Device and method for continuous extrusion-based fiber additive manufacturing |
PCT/NL2019/050372 WO2019245363A1 (en) | 2018-06-19 | 2019-06-18 | 3d printing device and 3d printing method with continuous extrusion-based fibre additive |
Publications (1)
Publication Number | Publication Date |
---|---|
EP3810386A1 true EP3810386A1 (en) | 2021-04-28 |
Family
ID=62873561
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19743065.5A Pending EP3810386A1 (en) | 2018-06-19 | 2019-06-18 | 3d printing device and 3d printing method with continuous extrusion-based fibre additive |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP3810386A1 (en) |
NL (1) | NL2021152B1 (en) |
WO (1) | WO2019245363A1 (en) |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3503972C1 (en) * | 1985-02-06 | 1986-08-14 | Helmut 2420 Eutin Krueger-Beuster | Device for producing fibre-reinforced thermoplastics profiles |
GB201304968D0 (en) * | 2013-03-19 | 2013-05-01 | Eads Uk Ltd | Extrusion-based additive manufacturing |
US9149988B2 (en) * | 2013-03-22 | 2015-10-06 | Markforged, Inc. | Three dimensional printing |
US10618217B2 (en) * | 2013-10-30 | 2020-04-14 | Branch Technology, Inc. | Cellular fabrication and apparatus for additive manufacturing |
EP3063341B1 (en) * | 2013-10-30 | 2021-03-24 | Branch Technology, Inc. | Additive manufacturing of buildings and other structures |
EP3218160A4 (en) * | 2014-11-14 | 2018-10-17 | Nielsen-Cole, Cole | Additive manufacturing techniques and systems to form composite materials |
CN107249864B (en) * | 2014-12-12 | 2019-09-27 | 尤利卡特基金会 | For manufacturing the method and system and thus obtained part of the part made of composite material |
KR101807794B1 (en) * | 2016-05-12 | 2017-12-08 | 국민대학교 산학협력단 | Three dimensional printer head for discharging multi printing materials and three dimensional printer having the same |
-
2018
- 2018-06-19 NL NL2021152A patent/NL2021152B1/en active
-
2019
- 2019-06-18 EP EP19743065.5A patent/EP3810386A1/en active Pending
- 2019-06-18 WO PCT/NL2019/050372 patent/WO2019245363A1/en unknown
Also Published As
Publication number | Publication date |
---|---|
NL2021152B1 (en) | 2020-01-06 |
WO2019245363A1 (en) | 2019-12-26 |
WO2019245363A8 (en) | 2020-04-23 |
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