The present invention relates to a method for preparing a three-dimensional shaped article, comprising the following steps: a) unfolding the three-dimensional profile of the three-dimensional shaped article with a curved surface via a computer-aided design software; b) dividing the unfolded three-dimensional profile obtained in step a) into several elemental layers via the computer-aided design software; c) cutting a continuous fiber reinforced thermoplastic resin based composite sheet to have the same or similar shape and size with the elemental layers; d) stacking the cut composite sheets in order of size to obtain a stack; and g) forming the stack obtained in step d), followed by demoulding and optionally trimming to obtain the three-dimensional shaped article. With the method of the present invention, a continuous fiber reinforced thermoplastic resin based composite sheet can be processed into a three-dimensional shaped article with uneven thickness and a high degree of curvature. The resulting three-dimensional shaped article features a light weight, good impact resistance and compression resistance.

The present invention relates to a method for preparing a three-dimensional shaped article, comprising the following steps: a) unfolding the three-dimensional profile of the three-dimensional shaped article with a curved surface via a computer-aided design software; b) dividing the unfolded three-dimensional profile obtained in step a) into several elemental layers via the computer-aided design software; c) cutting a continuous fiber reinforced thermoplastic resin based composite sheet to have the same or similar shape and size with the elemental layers; d) stacking the cut composite sheets in order of size to obtain a stack; and g) forming the stack obtained in step d), followed by demoulding and optionally trimming to obtain the three-dimensional shaped article. With the method of the present invention, a continuous fiber reinforced thermoplastic resin based composite sheet can be processed into a three-dimensional shaped article with uneven thickness and a high degree of curvature. The resulting three-dimensional shaped article features a light weight, good impact resistance and compression resistance.

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 a conduit 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 drag the filament from the conduit 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 a conduit 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 drag the filament from the conduit nozzle.

Methods, apparatuses, and systems for making prepregs are disclosed. A method may include depositing a resin material onto a surface of a fiber bed and forming a number of discrete resin regions thereon. A distance between the resin regions may be measured to provide desired exposed portions of the surface to facilitate permeation of air through the exposed portions of the surface in a direction perpendicular to a plane of the fiber bed during a curing process of the prepreg.

Methods, apparatuses, and systems for making prepregs are disclosed. A method may include depositing a resin material onto a surface of a fiber bed and forming a number of discrete resin regions thereon. A distance between the resin regions may be measured to provide desired exposed portions of the surface to facilitate permeation of air through the exposed portions of the surface in a direction perpendicular to a plane of the fiber bed during a curing process of the prepreg.

One embodiment is an apparatus including a mold configured to manufacture a composite structure at a heated temperature. The mold includes a first mold tool configured to mold a first portion of the composite structure, wherein the first mold tool comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands; and an anisotropic thermal expansion property, wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the first mold tool; and a second mold tool configured to mold a second portion of the composite structure.

A prepreg sheet includes a plurality of prepreg tapes each of which overlaps with a corresponding adjacent prepreg tape for a suitable overlapping length. The plurality of prepreg tapes each contain a reinforcing fiber bundle that is impregnated with a thermosetting resin composition. According to a method for manufacturing a preform, for example, a primary premolded article is manufactured by preforming an intermediate base material containing a reinforcing fiber base material and a matrix resin composition, and a secondary premolded article is manufactured by preforming the primary premolded article on which the intermediate base material is further placed.

A composite material forming device forms a composite material including a resin and reinforced fibers having electrical conductivity. The composite material forming device includes: a conduction jig having electrical conductivity, the conduction jig being to be placed on a surface of the composite material so as to make a bridge between both end portions of the reinforced fibers in a fiber direction; and an electric current generating unit that generates an electric current in the conduction jig. The conduction jig placed on the surface of the composite material and the reinforced fibers form a closed loop through which the electric current flows so that the closed loop intersects the surface of the composite material.

A composite material forming device forms a composite material including a resin and reinforced fibers having electrical conductivity. The composite material forming device includes: a conduction jig having electrical conductivity, the conduction jig being to be placed on a surface of the composite material so as to make a bridge between both end portions of the reinforced fibers in a fiber direction; and an electric current generating unit that generates an electric current in the conduction jig. The conduction jig placed on the surface of the composite material and the reinforced fibers form a closed loop through which the electric current flows so that the closed loop intersects the surface of the composite material.