Manufacture of a pre-impregnated fibrous material which contains continuous fibers and a thermoplastic matrix, the material being made as a plurality of unidirectional parallel ribbons or sheets, and the method involving a step of pre-impregnating, in dry conditions, N parallel strands divided into X groups of Ni strands, by the thermoplastic matrix in powder form in a tank, ΣNi=N et X 3, one thereof from each series being immersed in the powder, each group of strands running on the same number Y of tensioning parts, and the parallel strands being separated by a spacing at least equal to the width of each strand.

A shaping apparatus includes a stand that includes a shaping surface on which a product is shaped; a feeder that feeds a linear material obtained by impregnating continuous fiber with resin; a pressing portion that presses the material fed by the feeder against the stand; and an angle setting portion that sets an angle formed between the material fed from the feeder to the pressing portion and the shaping surface to be an acute angle.

A shaping apparatus includes a stand that includes a shaping surface on which a product is shaped; a feeder that feeds a linear material obtained by impregnating continuous fiber with resin; a pressing portion that presses the material fed by the feeder against the stand; and an angle setting portion that sets an angle formed between the material fed from the feeder to the pressing portion and the shaping surface to be an acute angle.

A method is disclosed for forming extrudate filament, which consist essentially of fiber, organic binder, and metal and/or ceramic. The extrudate filament can be spooled, or used to form preforms, and/or assemblages of preforms. In further methods, the extrudate filament and/or preforms can be used to fabricate fiber-reinforced metal-matrix or ceramic-matrix or metal and ceramic matrix composite parts, which consist essentially of fiber in a matrix of metal, or ceramic, or metal and ceramic, respectively.

A method is disclosed for forming extrudate filament, which consist essentially of fiber, organic binder, and metal and/or ceramic. The extrudate filament can be spooled, or used to form preforms, and/or assemblages of preforms. In further methods, the extrudate filament and/or preforms can be used to fabricate fiber-reinforced metal-matrix or ceramic-matrix or metal and ceramic matrix composite parts, which consist essentially of fiber in a matrix of metal, or ceramic, or metal and ceramic, respectively.

A microwave-induced heating of CNT filled (or coated) polymer composites for enhancing inter-bead diffusive bonding of fused filament fabricated parts. The technique incorporates microwave absorbing nanomaterials (carbon nanotubes (CNTs)) onto the surface or throughout the volume of 3D printer polymer filament to increase the inter-bead bond strength following a post microwave irradiation treatment and/or in-situ focused microwave beam during printing. The overall strength of the final 3D printed part will be dramatically increased and the isotropic mechanical properties of fused filament part will approach or exceed conventionally manufactured counterparts.

A microwave-induced heating of CNT filled (or coated) polymer composites for enhancing inter-bead diffusive bonding of fused filament fabricated parts. The technique incorporates microwave absorbing nanomaterials (carbon nanotubes (CNTs)) onto the surface or throughout the volume of 3D printer polymer filament to increase the inter-bead bond strength following a post microwave irradiation treatment and/or in-situ focused microwave beam during printing. The overall strength of the final 3D printed part will be dramatically increased and the isotropic mechanical properties of fused filament part will approach or exceed conventionally manufactured counterparts.

Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.

Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.

The present invention relates to a method for reducing an amount of glass filaments separating from pellets comprising a thermoplastic polymer sheath intimately surrounding the glass filaments. The method can include transporting the pellets through a piping system and/or by a vibrating conveyor means. The pellets have a length of at least 13 mm. The amount of glass filaments separating from the pellets when such pellets are subjected to repetitive mechanical loads in transportation is reduced as compared other pellets subjected to the same repetitive mechanical load, such that blocking caused by the glass filaments within the pellet transport system is reduced or eliminated as compared to transporting pellets having a length of less than or equal to 12.1 mm.