US20200180218A1 - Printed parts with interlayers and methods of manufacturing the same - Google Patents
Printed parts with interlayers and methods of manufacturing the same Download PDFInfo
- Publication number
- US20200180218A1 US20200180218A1 US16/787,171 US202016787171A US2020180218A1 US 20200180218 A1 US20200180218 A1 US 20200180218A1 US 202016787171 A US202016787171 A US 202016787171A US 2020180218 A1 US2020180218 A1 US 2020180218A1
- Authority
- US
- United States
- Prior art keywords
- layer
- layers
- interlay
- printed
- printable
- 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.)
- Abandoned
Links
- 238000004519 manufacturing process Methods 0.000 title abstract description 20
- 238000000034 method Methods 0.000 title description 12
- 239000011229 interlayer Substances 0.000 title description 3
- 239000000463 material Substances 0.000 claims abstract description 130
- 238000007639 printing Methods 0.000 abstract description 13
- 239000010410 layer Substances 0.000 description 131
- 238000001125 extrusion Methods 0.000 description 10
- 238000010146 3D printing Methods 0.000 description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 5
- 239000003365 glass fiber Substances 0.000 description 4
- 238000000110 selective laser sintering Methods 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- -1 filament Substances 0.000 description 3
- 230000000135 prohibitive effect Effects 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 239000011889 copper foil Substances 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 238000010586 diagram Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
Images
Classifications
-
- 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
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
-
- 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
- B33Y80/00—Products made by additive manufacturing
-
- 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
-
- 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
- B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
-
- 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
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
-
- 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
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/70—Completely encapsulating inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
-
- 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
- B33Y10/00—Processes of additive manufacturing
Definitions
- the present disclosure relates to the manufacturing of parts and, more specifically, to printed parts including interlay material layers and methods of manufacturing printed parts including interlay material layers.
- the present disclosure provides printed parts including interlay material layers that enable customization of the particular properties of the parts.
- the present disclosure also provides methods of manufacturing such printed parts.
- a method of manufacturing a part provided in accordance with the present disclosure includes printing a layer of 3D printable material, positioning a layer of interlay material on the layer of 3D printable material, and printing another layer of 3D printable material on the layer of interlay material.
- the method further includes positioning another layer of interlay material on another layer of 3D printable material and printing still another layer of 3D printable material on the another layer of interlay material. These steps may be repeated a plurality of times.
- the interlay material provides a property to the manufactured part not provided by the printed layers.
- the property may include, for example, conductivity, increased rigidity, or increased strength.
- the printing includes 3D printing via stereolithography, fused deposition modeling, or selective laser sintering.
- the positioning is performed manually.
- the positioning may be performed automatically.
- the layer of 3D printable material and the another layer of 3D printable material are formed from different 3D printable materials.
- the layer of 3D printable material and the another layer of 3D printable material are formed from the same 3D printable materials.
- the layer of 3D printable material defines a first thickness and the another layer of 3D printable material defines a second thickness different from the first thickness.
- the layer of 3D printable material and the another layer of 3D printable material define equal thicknesses.
- printing the another layer of 3D printable material fuses the layer of 3D printable material, the layer of interlay material, and the another layer of 3D printable material with one another.
- the interlay material is provided in one of: sheets, a roll, or loosely.
- a manufactured part provided in accordance with the present disclosure includes a base layer of 3D printable material and a plurality of pairs of alternating layers disposed on the base layer of 3D printable material.
- Each pair of the plurality of pairs includes a layer of interlay material and another layer of 3D printable material printed on the layer of interlay material.
- the layers of interlay material provide at least one property to the manufactured part not provided by the layers of 3D printable material.
- the property is conductivity, increased rigidity, or increased strength.
- FIG. 1 is a perspective view of a printed part including interlay material layers provided in accordance with aspects of the present disclosure
- FIG. 2 is an enlarged, perspective view of the area of detail indicated as “2” in
- FIG. 1 is a diagrammatic representation of FIG. 1 ;
- FIG. 3 is a schematic drawing illustrating a system for manufacturing a printed part including interlay material layers in accordance with aspects of the present disclosure.
- FIG. 4 is a flow diagram illustrating a method of manufacturing a printed part including interlay material layers in accordance with aspects of the present disclosure.
- Part 100 although illustrated as defining a rectangular box-like configuration, may define any suitable shape, dimensions, or other configuration, depending upon the purpose of part 100 .
- Part 100 more specifically, includes a plurality of first layers 110 and a plurality of second layers 120 .
- Part 100 may be formed via alternating first and second layers 110 , 120 , respectively, as illustrated, or may include other patterned or non-patterned arrangements of layers 110 , 120 .
- layers 110 , 120 may define similar thicknesses as other layers 110 , 120 of like and/or different kind, or may define different thicknesses as other layers 110 , 120 of like and/or different kind.
- each layer 110 , 120 may extend over only a portion of the entirety of part 100 , and/or different layers 110 , 120 may extend over different portions of part 100 in order to achieve a desired configuration of part 100
- Each of the plurality of first layers 110 is formed via printing, e.g., 3D printing, and may be formed from any suitable material, or combination of materials.
- each of the first layers 110 may be formed from a high-temperature grade 3D printable plastic or other commercially available 3D printable material.
- Each of the plurality of first layers 110 may be formed from the same material or combination of materials, or some of first layers 110 may be formed from different materials or different combinations of materials from other first layers 110 .
- the plurality of first layers 110 may be printed from a resin using stereolithography (SLA), may be printed from filament via fused deposition modeling (FDM), may be printed from a powder using selective laser sintering (SLS), or may be printed from a combination of resin, filament, and/or powder using SLA, SFM, and/or SLS, respectively.
- SLA stereolithography
- FDM fused deposition modeling
- SLS selective laser sintering
- Printing the first layers 110 is advantageous in that it enables the first layers 110 to be customized to a particular configuration, e.g., shape, dimensions, etc., without the need for tooling or other dedicated manufacturing equipment.
- Each first layer 110 more specifically, is printed from a digital model file (e.g., created on a general purpose computer with suitable CAD software) designed based upon the desired configuration of that particular first layer 110 or group of first layers 110 .
- CAD software e.g., created on a general purpose computer with suitable CAD software
- part 100 further includes, as noted above, a plurality of second layers 120 formed differently from first layers 110 .
- Each second layer 120 is formed from an interlay material or materials configured to provide properties to part 100 that are difficult, time-consuming, and/or cost prohibitive to provide via printing.
- the interlay material of some or all of second layers 120 may be, for example, glass fiber cloth, glass fiber mat, copper foil, mesh copper, mesh steel, plastic sheet, combinations thereof, etc.
- Utilizing copper, e.g., copper foil or mesh copper, as the interlay material of at least one of the second layers 120 enables part 100 to be conductive, thus enabling electrical connections between part 100 and another part or parts.
- utilizing glass, e.g., glass fiber cloth or glass fiber mat, as the interlay material of at least one of the second layers 120 provides increased rigidity to part 100 .
- Utilizing steel, e.g., mesh steel, as the interlay material of at least one of the second layers 120 provides increased strength to part 100 .
- the above interlay materials and properties provided thereby are merely exemplary, as any suitable interlay material(s) may be utilized to provide a desired property or set of properties to part 100 .
- the manufacturing process for forming second layers 120 depends upon the interlay material or materials utilized to form second layers 120 . Further, the interlay material may be formed separately and thereafter assembled on the other, previously-assembled layers 110 , 120 to form the next second layer 120 , or may be formed and assembled on the other, previously-assembled layers 110 , 120 to form the next second layer 120 as part of the same step, e.g., simultaneously or near-simultaneously.
- Each second layer 120 may be defined by a plurality of layers of interlay material(s), in embodiments where the interlay material is formable into layers, or may be formed with a desired thickness, in embodiments where the interlay material is not formable into layers.
- the interlay material may be provided as a sheet of material, a roll of material, loosely in a container, as a plurality of strips, rods, bars, or other components to be arranged in a particular pattern, or in other suitable form to facilitate positioning the interlay material on the other layers 110 , 120 to form a second layer 120 .
- System 200 includes a 3D printer 210 configured, as illustrated, for FDM 3D printing, although other suitable 3D printers are also contemplated.
- System 200 further includes a build platform 220 for supporting the part 100 to be manufactured, and a supply of interlay material 230 , which, as noted above, may be sheets of material (stacked, as shown), as a roll of material, or in other suitable form.
- System 200 further includes a computer 240 configured to control the 3D printing process based upon the digital model file input thereto to manufacture the part 100 in accordance with the digital model file.
- FDM 3D printer 210 generally includes a filament supply 212 , which may be in the form of a spool, an extrusion head 214 that is movable in two axial directions over build platform 220 and is configured to heat the filament provided by the filament supply 212 , and an extrusion nozzle 216 attached to extrusion head 214 for extruding the heated filament onto the build platform 220 or portion of the part 100 that has already been built.
- multiple filament supplies 212 may be provided.
- extrusion head 214 may further be configured to move vertically.
- Build platform 220 is configured to support the part 100 to be manufactured thereon, as noted above.
- build platform 220 may be configured to move vertically, e.g., towards or way from extrusion nozzle 216 , to define a desired spacing between extrusion nozzle 216 and the part 100 to be manufactured.
- build platform 220 is configured to move in two additional axial directions, thus obviating the need for extrusion head 214 to do so, although any combination of motion between build platform 220 and extrusion head 214 to achieve motion in all three coordinate axial directions are contemplated.
- With respect to vertical adjustment for example, as the part 100 is manufactured and, thus, increases in height, build platform 220 may be lowered (and/or extrusion head 214 raised) to maintain a desired spacing between extrusion nozzle 216 and the part 100 .
- the FDM 3D printer 210 is configured to print the first plurality of layers 110 , starting with a base first layer 110 , on the build platform 220 .
- the supply of interlay material 230 is utilized to form the plurality of second layers 120 and, as noted above, may be interlayed such that the first and second layers 110 , 120 define an alternating configuration (as illustrated), or may be interlayed in any other suitable configuration. In embodiments where multiple interlay materials are utilized to form the second layers 120 and/or different second layers 120 , multiple supplies of interlay material 230 may be provided.
- a suitable number of sheets of interlay material from the supply of interlay material 230 are disposed on the base first layer 110 to form a second layer 120 of interlay material. Disposing the interlay material on the base first layer 110 to form the second layer 120 of interlay material may be performed manually or may be performed automatically using suitable machinery. In automatic embodiments, the machinery utilized may be controlled by computer 240 to provide a fully automated and centrally-controlled system of manufacturing part 100 with layers 110 , 120 .
- the interlay material may be disposed on the base first layer 110 in an manner suitable for that particular interlay material.
- an intermediate first layer 110 is printed from 3D printer 210 on top of the second layer 120 of interlay material.
- Printing the intermediate first layer 110 on top of the second layer 120 of interlay material causes the intermediate first layer 110 to encapsulate, penetrate, and/or otherwise fuse with the second layer 120 and the base first layer 110 below the second layer 120 to thereby form an integral portion of part 100 .
- the intermediate first layer 110 penetrates the second layer 120 to fuse the layers to one another.
- the second layer 120 may be dimensioned slightly smaller than the first layers 110 to enable the intermediate first layer 110 to encapsulate the second layer 120 .
- FIG. 4 a method of manufacturing a part, e.g., part 100 ( FIG. 1 ), is described.
- the method of manufacturing detailed below may be effectuated using system 200 ( FIG. 3 ), as detailed above, or using any other suitable equipment, and may utilize any suitable materials, such as those detailed above or other materials.
- a base layer of 3D printed material is 3D printed.
- interlay material is positioned on the base layer of 3D printed material to form an interlay material layer.
- an intermediate layer of 3D printed material is 3D printed onto the interlay material layer to fuse the base 3D printed layer, the interlay material layer, and the intermediate 3D printed layer into an integral component.
- another interlay material is positioned on the intermediate layer of 3D printed material.
- steps 430 and 440 may be repeated any suitable number of times, in order to provide a desired amount of intermediate layer pairs, e.g., intermediate 3D printed material layer and interlay material layer pairs.
- a top layer of 3D printed material is 3D printed onto the top-most interlay material layer to form the completed, integral part.
- steps 420 , 430 , and 440 rather than providing steps 420 , 430 , and 440 , only a single interlay material layer is provided between the base and top layers of 3D printed material.
Abstract
Description
- This application is a divisional of U.S. patent application Ser. No. 15/807,161 entitled “PRINTED PARTS WITH INTERLAYERS AND METHODS OF MANUFACTURING THE SAME” and filed on Nov. 8, 2017, which claims the benefit of, and priority to, U.S. Provisional Patent Application No. 62/418,900, entitled “METHOD TO REINFORCE 3D PRINTED PARTS WITH HIGH STRENGTH INTERLAYERS” and filed on Nov. 8, 2016, the entire contents of which are hereby incorporated herein by reference.
- The present disclosure relates to the manufacturing of parts and, more specifically, to printed parts including interlay material layers and methods of manufacturing printed parts including interlay material layers.
- The manufacture of parts via printed processes, e.g., 3D printing, is advantageous in that it eliminates the need for expensive tooling and enables the creation of parts of almost any shape or geometry from a digital model file. However, printed processes are restrictive in that the types of readily available materials that can be printed are limited and specific formulations of materials are either unavailable or cost prohibitive. As a result, printed parts are not readily customizable to have particular material properties.
- It would therefore be desirable to have the ability to manufacture parts via a printed process, e.g., 3D printing, that are readily customizable to have particular material properties.
- The present disclosure provides printed parts including interlay material layers that enable customization of the particular properties of the parts. The present disclosure also provides methods of manufacturing such printed parts. These and other aspects and features of the present disclosure are detailed below. To the extent consistent, any of the aspects and features described herein may be used in conjunction with any or all of the other aspects and features described herein.
- A method of manufacturing a part provided in accordance with the present disclosure includes printing a layer of 3D printable material, positioning a layer of interlay material on the layer of 3D printable material, and printing another layer of 3D printable material on the layer of interlay material.
- In an aspect of the present disclosure, the method further includes positioning another layer of interlay material on another layer of 3D printable material and printing still another layer of 3D printable material on the another layer of interlay material. These steps may be repeated a plurality of times.
- In another aspect of the present disclosure, the interlay material provides a property to the manufactured part not provided by the printed layers. The property may include, for example, conductivity, increased rigidity, or increased strength.
- In another aspect of the present disclosure, the printing includes 3D printing via stereolithography, fused deposition modeling, or selective laser sintering.
- In still another aspect of the present disclosure, the positioning is performed manually. Alternatively, the positioning may be performed automatically.
- In yet another aspect of the present disclosure, the layer of 3D printable material and the another layer of 3D printable material are formed from different 3D printable materials. Alternatively, the layer of 3D printable material and the another layer of 3D printable material are formed from the same 3D printable materials.
- In still yet another aspect of the present disclosure, the layer of 3D printable material defines a first thickness and the another layer of 3D printable material defines a second thickness different from the first thickness. Alternatively, the layer of 3D printable material and the another layer of 3D printable material define equal thicknesses.
- In another aspect of the present disclosure, printing the another layer of 3D printable material fuses the layer of 3D printable material, the layer of interlay material, and the another layer of 3D printable material with one another.
- In yet another aspect of the present disclosure, the interlay material is provided in one of: sheets, a roll, or loosely.
- A manufactured part provided in accordance with the present disclosure includes a base layer of 3D printable material and a plurality of pairs of alternating layers disposed on the base layer of 3D printable material. Each pair of the plurality of pairs includes a layer of interlay material and another layer of 3D printable material printed on the layer of interlay material. The layers of interlay material provide at least one property to the manufactured part not provided by the layers of 3D printable material.
- In aspects of the present disclosure, the property is conductivity, increased rigidity, or increased strength.
- Various aspects and features of the present disclosure are described hereinbelow with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views and:
-
FIG. 1 is a perspective view of a printed part including interlay material layers provided in accordance with aspects of the present disclosure; -
FIG. 2 is an enlarged, perspective view of the area of detail indicated as “2” in -
FIG. 1 ; -
FIG. 3 is a schematic drawing illustrating a system for manufacturing a printed part including interlay material layers in accordance with aspects of the present disclosure; and -
FIG. 4 is a flow diagram illustrating a method of manufacturing a printed part including interlay material layers in accordance with aspects of the present disclosure. - Referring to
FIGS. 1 and 2 , a part provided in accordance with the present disclosure is shown generally identified byreference numeral 100.Part 100, although illustrated as defining a rectangular box-like configuration, may define any suitable shape, dimensions, or other configuration, depending upon the purpose ofpart 100.Part 100, more specifically, includes a plurality offirst layers 110 and a plurality ofsecond layers 120.Part 100 may be formed via alternating first andsecond layers layers layers other layers other layers layer part 100, and/ordifferent layers part 100 in order to achieve a desired configuration ofpart 100 - Each of the plurality of
first layers 110 is formed via printing, e.g., 3D printing, and may be formed from any suitable material, or combination of materials. For example, each of thefirst layers 110 may be formed from a high-temperature grade 3D printable plastic or other commercially available 3D printable material. Each of the plurality offirst layers 110 may be formed from the same material or combination of materials, or some offirst layers 110 may be formed from different materials or different combinations of materials from otherfirst layers 110. Further, the plurality offirst layers 110 may be printed from a resin using stereolithography (SLA), may be printed from filament via fused deposition modeling (FDM), may be printed from a powder using selective laser sintering (SLS), or may be printed from a combination of resin, filament, and/or powder using SLA, SFM, and/or SLS, respectively. - Printing the
first layers 110 is advantageous in that it enables thefirst layers 110 to be customized to a particular configuration, e.g., shape, dimensions, etc., without the need for tooling or other dedicated manufacturing equipment. Eachfirst layer 110, more specifically, is printed from a digital model file (e.g., created on a general purpose computer with suitable CAD software) designed based upon the desired configuration of that particularfirst layer 110 or group offirst layers 110. However, depending upon the desired properties ofpart 100, it may be difficult, time consuming, and/or cost prohibitive to createpart 100 to include the desired properties while forming the part entirely from printing. That is, formulating specific materials or combinations of materials capable of being 3D printed and also exhibiting the desired properties is difficult, time consuming, and/or costly. - Referring still to
FIGS. 1 and 2 , in order to facilitate manufacture ofpart 100 to include properties not readily achievable by formingpart 100 entirely from printing,part 100 further includes, as noted above, a plurality ofsecond layers 120 formed differently fromfirst layers 110. Eachsecond layer 120, more specifically, is formed from an interlay material or materials configured to provide properties topart 100 that are difficult, time-consuming, and/or cost prohibitive to provide via printing. The interlay material of some or all ofsecond layers 120 may be, for example, glass fiber cloth, glass fiber mat, copper foil, mesh copper, mesh steel, plastic sheet, combinations thereof, etc. Utilizing copper, e.g., copper foil or mesh copper, as the interlay material of at least one of thesecond layers 120, for example, enablespart 100 to be conductive, thus enabling electrical connections betweenpart 100 and another part or parts. As another example, utilizing glass, e.g., glass fiber cloth or glass fiber mat, as the interlay material of at least one of thesecond layers 120, provides increased rigidity topart 100. Utilizing steel, e.g., mesh steel, as the interlay material of at least one of thesecond layers 120, as another example, provides increased strength topart 100. However, the above interlay materials and properties provided thereby are merely exemplary, as any suitable interlay material(s) may be utilized to provide a desired property or set of properties topart 100. - The manufacturing process for forming
second layers 120 depends upon the interlay material or materials utilized to formsecond layers 120. Further, the interlay material may be formed separately and thereafter assembled on the other, previously-assembledlayers second layer 120, or may be formed and assembled on the other, previously-assembledlayers second layer 120 as part of the same step, e.g., simultaneously or near-simultaneously. Eachsecond layer 120 may be defined by a plurality of layers of interlay material(s), in embodiments where the interlay material is formable into layers, or may be formed with a desired thickness, in embodiments where the interlay material is not formable into layers. Depending upon the particular interlay material or materials utilized, the interlay material may be provided as a sheet of material, a roll of material, loosely in a container, as a plurality of strips, rods, bars, or other components to be arranged in a particular pattern, or in other suitable form to facilitate positioning the interlay material on theother layers second layer 120. - Turning now to
FIG. 3 , a system for manufacturingpart 100 in accordance with the present disclosure is illustrated generally assystem 200.System 200 includes a3D printer 210 configured, as illustrated, for FDM 3D printing, although other suitable 3D printers are also contemplated.System 200 further includes abuild platform 220 for supporting thepart 100 to be manufactured, and a supply ofinterlay material 230, which, as noted above, may be sheets of material (stacked, as shown), as a roll of material, or in other suitable form.System 200 further includes acomputer 240 configured to control the 3D printing process based upon the digital model file input thereto to manufacture thepart 100 in accordance with the digital model file. -
FDM 3D printer 210 generally includes afilament supply 212, which may be in the form of a spool, anextrusion head 214 that is movable in two axial directions overbuild platform 220 and is configured to heat the filament provided by thefilament supply 212, and anextrusion nozzle 216 attached toextrusion head 214 for extruding the heated filament onto thebuild platform 220 or portion of thepart 100 that has already been built. In embodiments where multiple materials are 3D printed, e.g., where the plurality offirst layers 110 are formed from a combination of materials and/or differentfirst layers 110 are formed from different materials, multiple filament supplies 212 may be provided. In embodiments,extrusion head 214 may further be configured to move vertically. -
Build platform 220 is configured to support thepart 100 to be manufactured thereon, as noted above. In embodiments,build platform 220 may be configured to move vertically, e.g., towards or way fromextrusion nozzle 216, to define a desired spacing betweenextrusion nozzle 216 and thepart 100 to be manufactured. In embodiments,build platform 220 is configured to move in two additional axial directions, thus obviating the need forextrusion head 214 to do so, although any combination of motion betweenbuild platform 220 andextrusion head 214 to achieve motion in all three coordinate axial directions are contemplated. With respect to vertical adjustment, for example, as thepart 100 is manufactured and, thus, increases in height,build platform 220 may be lowered (and/orextrusion head 214 raised) to maintain a desired spacing betweenextrusion nozzle 216 and thepart 100. - Continuing with reference to
FIG. 3 , theFDM 3D printer 210 is configured to print the first plurality oflayers 110, starting with a basefirst layer 110, on thebuild platform 220. The supply ofinterlay material 230 is utilized to form the plurality ofsecond layers 120 and, as noted above, may be interlayed such that the first andsecond layers second layers 120 and/or differentsecond layers 120, multiple supplies ofinterlay material 230 may be provided. - In the embodiment illustrated in
FIG. 3 , once the basefirst layer 110 is printed, a suitable number of sheets of interlay material from the supply ofinterlay material 230 are disposed on the basefirst layer 110 to form asecond layer 120 of interlay material. Disposing the interlay material on the basefirst layer 110 to form thesecond layer 120 of interlay material may be performed manually or may be performed automatically using suitable machinery. In automatic embodiments, the machinery utilized may be controlled bycomputer 240 to provide a fully automated and centrally-controlled system ofmanufacturing part 100 withlayers first layer 110 in an manner suitable for that particular interlay material. - With the
second layer 120 of interlay material positioned as detailed above, an intermediatefirst layer 110 is printed from3D printer 210 on top of thesecond layer 120 of interlay material. Printing the intermediatefirst layer 110 on top of thesecond layer 120 of interlay material causes the intermediatefirst layer 110 to encapsulate, penetrate, and/or otherwise fuse with thesecond layer 120 and the basefirst layer 110 below thesecond layer 120 to thereby form an integral portion ofpart 100. More specifically, where thesecond layer 120 is porous, the intermediatefirst layer 110 penetrates thesecond layer 120 to fuse the layers to one another. On the other hand, where thesecond layer 120 is not porous, thesecond layer 120 may be dimensioned slightly smaller than thefirst layers 110 to enable the intermediatefirst layer 110 to encapsulate thesecond layer 120. Other suitable configurations to facilities the fusion of the layers with one another are also contemplated such as, for example, perforations in thesecond layer 120. As can be appreciated, the above-detailed process is repeated, alternating between (or otherwise arranging)second layers 120 of interlay material and intermediatefirst layers 110 until a final, topfirst layer 110 is printed on the top-mostsecond layer 120 of interlay material to complete manufacture of thepart 100. - Turning now to
FIG. 4 , a method of manufacturing a part, e.g., part 100 (FIG. 1 ), is described. The method of manufacturing detailed below may be effectuated using system 200 (FIG. 3 ), as detailed above, or using any other suitable equipment, and may utilize any suitable materials, such as those detailed above or other materials. - Initially, at
step 410, a base layer of 3D printed material is 3D printed. Atstep 420, interlay material is positioned on the base layer of 3D printed material to form an interlay material layer. Atstep 430, an intermediate layer of 3D printed material is 3D printed onto the interlay material layer to fuse the base 3D printed layer, the interlay material layer, and the intermediate 3D printed layer into an integral component. Atstep 440, another interlay material is positioned on the intermediate layer of 3D printed material. As indicated atstep 450,steps step 460, a top layer of 3D printed material is 3D printed onto the top-most interlay material layer to form the completed, integral part. In other embodiments, rather than providingsteps - Persons skilled in the art will understand that the structures and methods specifically described herein and shown in the accompanying figures are non-limiting exemplary embodiments, and that the description, disclosure, and figures should be construed merely as exemplary of particular embodiments. It is to be understood, therefore, that the present disclosure is not limited to the precise embodiments described, and that various other changes and modifications may be affected by one skilled in the art without departing from the scope or spirit of the disclosure. Additionally, the elements and features shown or described in connection with certain embodiments may be combined with the elements and features of certain other embodiments without departing from the scope of the present disclosure, and that such modifications and variations are also included within the scope of the present disclosure. Accordingly, the subject matter of the present disclosure is not limited by what has been particularly shown and described.
Claims (4)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/787,171 US20200180218A1 (en) | 2016-11-08 | 2020-02-11 | Printed parts with interlayers and methods of manufacturing the same |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201662418900P | 2016-11-08 | 2016-11-08 | |
US15/807,161 US10828828B2 (en) | 2016-11-08 | 2017-11-08 | Method of manufacturing a part |
US16/787,171 US20200180218A1 (en) | 2016-11-08 | 2020-02-11 | Printed parts with interlayers and methods of manufacturing the same |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/807,161 Division US10828828B2 (en) | 2016-11-08 | 2017-11-08 | Method of manufacturing a part |
Publications (1)
Publication Number | Publication Date |
---|---|
US20200180218A1 true US20200180218A1 (en) | 2020-06-11 |
Family
ID=62065360
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/807,161 Active 2038-06-20 US10828828B2 (en) | 2016-11-08 | 2017-11-08 | Method of manufacturing a part |
US16/787,171 Abandoned US20200180218A1 (en) | 2016-11-08 | 2020-02-11 | Printed parts with interlayers and methods of manufacturing the same |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/807,161 Active 2038-06-20 US10828828B2 (en) | 2016-11-08 | 2017-11-08 | Method of manufacturing a part |
Country Status (1)
Country | Link |
---|---|
US (2) | US10828828B2 (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2023150602A1 (en) * | 2022-02-03 | 2023-08-10 | Formlabs Inc. | Composite material reinforced stereolithography methods and systems |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4888247A (en) * | 1986-08-27 | 1989-12-19 | General Electric Company | Low-thermal-expansion, heat conducting laminates having layers of metal and reinforced polymer matrix composite |
US5567535A (en) * | 1992-11-18 | 1996-10-22 | Mcdonnell Douglas Corporation | Fiber/metal laminate splice |
US8354170B1 (en) * | 2009-10-06 | 2013-01-15 | Hrl Laboratories, Llc | Elastomeric matrix composites |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5705117A (en) * | 1996-03-01 | 1998-01-06 | Delco Electronics Corporaiton | Method of combining metal and ceramic inserts into stereolithography components |
DE19964099B4 (en) * | 1999-12-31 | 2006-04-06 | Götzen, Reiner, Dipl.-Ing. | Method for producing three-dimensionally arranged guide and connection structures for volume and energy flows |
US20020171177A1 (en) * | 2001-03-21 | 2002-11-21 | Kritchman Elisha M. | System and method for printing and supporting three dimensional objects |
US20080006966A1 (en) * | 2006-07-07 | 2008-01-10 | Stratasys, Inc. | Method for building three-dimensional objects containing metal parts |
US8858856B2 (en) * | 2008-01-08 | 2014-10-14 | Stratasys, Inc. | Method for building and using three-dimensional objects containing embedded identification-tag inserts |
-
2017
- 2017-11-08 US US15/807,161 patent/US10828828B2/en active Active
-
2020
- 2020-02-11 US US16/787,171 patent/US20200180218A1/en not_active Abandoned
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4888247A (en) * | 1986-08-27 | 1989-12-19 | General Electric Company | Low-thermal-expansion, heat conducting laminates having layers of metal and reinforced polymer matrix composite |
US5567535A (en) * | 1992-11-18 | 1996-10-22 | Mcdonnell Douglas Corporation | Fiber/metal laminate splice |
US8354170B1 (en) * | 2009-10-06 | 2013-01-15 | Hrl Laboratories, Llc | Elastomeric matrix composites |
Also Published As
Publication number | Publication date |
---|---|
US10828828B2 (en) | 2020-11-10 |
US20180126633A1 (en) | 2018-05-10 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
JP6839169B2 (en) | Ceramic filter and its forming method | |
US10029422B2 (en) | Three-dimensional modelling and/or manufacturing apparatus, and related processes | |
US6702918B2 (en) | Intermittent material feed type variable-lamination rapid prototyping process and apparatus using linear thermal cutting system | |
US11229605B2 (en) | Printed support structure | |
JP6384826B2 (en) | Three-dimensional additive manufacturing apparatus, three-dimensional additive manufacturing method, and three-dimensional additive manufacturing program | |
US20150231830A1 (en) | Device of color 3d printing and method thereof | |
Kudelski et al. | Comparison of cost, material and time usage in FDM and SLS 3D printing methods | |
US10583647B2 (en) | Method of controlling warping in 3D printing | |
CN104708814B (en) | Three-dimensional printing device | |
US20200180218A1 (en) | Printed parts with interlayers and methods of manufacturing the same | |
US20210197462A1 (en) | Topographic build plate for additive manufacturing system | |
CN111590874A (en) | Printing method of three-dimensional printer | |
US20210096535A1 (en) | Multi-tool fabrication machine | |
WO2020065653A1 (en) | Method and system for additive manufacturing with a sacrificial structure for easy removal | |
US10386799B2 (en) | Method and system for defining a 3D printed object | |
KR102236112B1 (en) | Method for three-dimensional printing in a partial area of bed and three-dimensional printer used in the method | |
US20170312823A1 (en) | Honeycomb structure and method of making same | |
JP2004124201A (en) | Method of laser beam lithography using metal powder | |
JP2018020547A (en) | Molding stage of three-dimensional molded object, apparatus for manufacturing three-dimensional molded object, and method for manufacturing three-dimensional molded object | |
CN106671399A (en) | Method for obtaining structural design parameters | |
KR102067873B1 (en) | Method for calculating metal powder supply rate of 3d printer | |
US20180078888A1 (en) | Ceramic filter and method for forming the filter | |
JP6824428B2 (en) | Input data creation device for metal powder additive manufacturing | |
US11298885B2 (en) | Three-dimensionally article with knock out support defined with build material | |
JP6524318B1 (en) | Shaper, and method of manufacturing shaped object |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: FLEX LTD, SINGAPORE Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:MEHKRI, ZOHAIR;MOHAMMED, ANWAR;TAN, JESUS;AND OTHERS;SIGNING DATES FROM 20171103 TO 20171110;REEL/FRAME:052082/0496 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE AFTER FINAL ACTION FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: ADVISORY ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE AFTER FINAL ACTION FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: ADVISORY ACTION MAILED |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |