Method and Apparatus for Additive Manufacturing Using Filament Shaping

Abstract

A method and apparatus for additive manufacturing wherein a fiber composite filament having an arbitrarily shaped cross section is softened and then flattened to tape-like form factor for incorporation into a part that is being additively manufactured.

Claims

1. A method for additive manufacturing, comprising: depositing a first composite filament on a build surface; softening the first composite filament, wherein, after softening, the first composite filament retains an ability to be shaped; and flattening the first composite filament.

2. The method of claim 1 wherein softening the first composite filament further comprises softening the first composite filament and at least partially melting a second composite filament that underlies the first composite filament.

3. The method of claim 2 wherein softening the first composite filament further comprises softening the first composite filament and at least partially melting the second composite filament concurrently.

4. The method of claim 1 wherein softening the first composite filament further comprises exposing the first composite filament to heat from a focused heat source.

5. The method of claim 3 and further wherein a heat source used to soften the first composite filament is the same heat source that is used to at least partially melt the second composite filament.

6. The method of claim 1 wherein softening the first composite filament further comprises partially melting a lower portion of the first composite filament and partially melting an upper portion of the second composite filament.

7. The method of claim 6 wherein softening the first composite filament further comprises melting the lower portion of the first composite filament to an amount up to 50 percent of a thickness of the first composite filament prior to flattening.

8. The method of claim 1 wherein flattening the first composite filament further comprises altering a shape of a cross section thereof while maintaining a cross-sectional area thereof.

9. The method of claim 1 wherein flattening the first composite filament further comprises applying pressure thereto.

10. The method of claim 1 wherein flattening the first composite filament further comprises positioning the first composite filament in a path of a roller.

11. A method for additive manufacturing, comprising: delivering, without a change in cross-sectional area, a composite filament onto a build surface; and reshaping the composite filament, wherein, before reshaping, the composite filament has a substantially circular cross section and after reshaping, the composite filament is flattened.

12. The method of claim 11 wherein reshaping the composite filament further comprises softening, but not completely melting the composite filament.

13. The method of claim 12 and further wherein, after softening, the composite filament retains an ability to be shaped.

14. The method of claim 12 and further wherein reshaping the composite filament further comprises compressing the softened filament, thereby flattening same.

15. The method of claim 11 wherein reshaping the composite filament further comprises illuminating, with laser light from a single laser, the composite filament and a second composite filament that underlies and abuts the composite filament, wherein the laser light melts at least a portion of the second composite filament and at least a portion of the composite filament.

16. The method of claim 15 wherein reshaping the composite filament further comprises compressing the composite filament.

17. An apparatus for additive manufacturing of a part, comprising: a positioning subsystem, wherein the positioning subsystem delivers a composite filament to an arbitrary location in space, as specified in accordance with build instructions for the part; a feed subsystem, wherein the feed subsystem delivers the composite filament to a build surface; a focused heat source, wherein the focused heat source softens the composite filament, the thermoplastic filament retaining an ability to be shaped; and a shaper, wherein the shaper applies pressure to the composite filament, reshaping same.

18. The apparatus of claim 17 and further wherein the shaper alters a cross sectional shape of the composite filament, but a cross sectional area of the composite filament is constant before and after alteration thereof.

19. The apparatus of claim 17 wherein the focused heat source is a laser.

20. The apparatus of claim 17 wherein the shaper comprises a roller.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIGS. 1A -1D depict various paths that can be followed, and profiles and surfaces that can be formed, via embodiments of the present invention.

[0026] FIG. 2 depicts a block diagram of the salient components of an additive manufacturing system that employs composite filament shaping in accordance with an illustrative embodiment of the present invention.

[0027] FIG. 3 depicts an illustrative embodiment of the additive manufacturing system of FIG. 2.

[0028] FIG. 4 depicts a method for additive manufacturing in accordance with an illustrative embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0029] FIG. 2 depicts the salient functional elements of deposition system 200 in accordance with the present invention. Included in system 200 are positioning subsystem 202, feed subsystem 204, focused heat source 206, and shaper 210.

[0030] In the illustrative embodiment, positioning subsystem 202 comprises a multi-axis end effector (e.g., robotic arm, etc.). In the illustrative embodiment, the multi-axis end effector has sufficient degrees of freedom (i.e., six DOF) to enable true three-dimensional printing. That is, the positioning subsystem is capable of delivering a feed filament to an arbitrary location in space, as specified in accordance with the build instructions. This enables system 200 to print along the natural loading contours of an part. Printing with such a multi-axis end effector is described, for example, in Ser. No. 14/184,010, previously referenced and incorporated by reference herein.

[0031] In some other embodiments, positioning subsystem 202 comprises a gantry having one or two translational degrees of freedom (x and/or y axes). In some of such embodiments, a build plate, on which the part is printed, is also considered to be part of the positioning subsystem. In such embodiments, the build plate is movable in the z direction (and possibly the x or y direction depending on gantry capabilities), such that three degrees of freedom are provided for the build. In some further embodiments, a robotic arm can be supported by a gantry. It is within the capabilities of those skilled in the art to design or specify a robotic arm, other multi-axis end effector, or gantry system to provide the requisite functionality for system 200.

[0032] Feed subsystem 204 delivers a filament to a build surface (e.g., a build plate, previously deposited layers of filament, etc.). In the illustrative embodiment, the composite filament is a cylindrical towpreg consisting of a continuous fiber (e.g., 1K, 3K, 6K, 12K, 24K, etc.) impregnated with thermoplastic resin. The continuous fiber includes, without limitation, carbon, fiberglass, aramid (AKA Kevlar), or carbon nanotubes (CNT).

[0033] The thermoplastic can be a semi-crystalline polymer or a mixture of a semi-crystalline polymer and an amorphous polymer. The semi-crystalline material can be, for example and without limitation, a polyaryletherketone (PAEK), such as polyetherketone (PEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetheretherketoneketone (PEEKK), and polyetherketoneetherketoneketone (PEKEKK). The semi-crystalline polymer can also be other semi-crystalline thermoplastics, for example and without limitation, polyamide (PA), polybutylene terephthalate (PBT), poly(p-phenylene sulfide) (PPS).

[0034] In embodiments in which the feed is a blend of an amorphous polymer with a semi-crystalline polymer, the semi-crystalline polymer can be one of the aforementioned materials and the amorphous polymer can be a polyarylsulfone, such as polysulfone (PSU), polyethersulfone (PESU), polyphenylsulfone (PPSU), polyethersulfone (PES), polyetherimide (PEI). In some additional embodiments, the amorphous polymer can be, for example and without limitation, polyphenylene oxides (PPOs), acrylonitrile butadiene styrene (ABS), methyl methacrylate acrylonitrile butadiene styrene copolymer (ABSi), polystyrene (PS), and polycarbonate (PC).

[0035] In the blend, the weight ratio of semi-crystalline material to amorphous material is in a range of about 50:50 to about 95:05, inclusive, or about 50:50 to about 90:10, inclusive. Preferably, the weight ratio of semi-crystalline material to amorphous material in the blend is between 60:40 and 80:20, inclusive. The ratio selected for any particular application is primarily a function of the materials used and the properties desired for the printed part.

[0036] Focused heat source 206 provides accurate control of the processing temperature of the composite filament. In the illustrative embodiment, the focused heat source is a laser. The beam spot size of a laser is precisely controllable. In accordance with the illustrative embodiment, such precise control of beam-spot size enables the laser to be aligned to heat at least a portion of a previously deposited (underlying) layer of filament to melting while, at the same time, softening (but not melting) or only partially melting the filament being deposited.

[0037] In the illustrative embodiment, focused heat source 206 precisely heats the composite filament above its glass transition temperature up to its melting temperature. In the illustrative embodiment, the resin in the composite filament is either not melted, or not completely melted, such that resin does not flow (or flow minimally) out of the filament (e.g., carbon fiber, etc.). This prevents or reduces the loss of wetting associated with movement of the polymer resin out of the fiber, as previously discussed. The temperature at which any particular composite filament feedstock softens is a function of its composition. Those skilled in the art can readily determine a desired “softening” temperature by simple experimentation.

[0038] After softening, the composite filament is reshaped. In particular, the composite filament is flattened so that it acquires a more tape-like form. As previously noted, the flattened form is desirable for a composite filament because this shape is conducive to the additive manufacturing process and produces parts with better material properties as compared to those built from composite filaments having substantially circular cross sections.

[0039] In some embodiments of the invention, the underlying filament is at least partially melted. By doing so, the bonding and adhesion between the underlying filament and the just-deposited, overlying filament increases, enhancing the overall mechanical properties of the nascent part.

[0040] In some embodiments in which the underlying filament is at least partially melted, the portion that is partially melted is the portion adjacent to the overlying filament. In some embodiments, a portion of the just-deposited (overlying) filament is melted. In some of such embodiments, the melted portion is the “lower” portion of the composite filament. Thus, in some embodiments, an “upper” portion of the underlying filament is melted and a “lower” portion of the overlying filament is melted. It is to be understood that the fiber doesn't melt; rather, the thermoplastic in and around the fiber melts.

[0041] In some embodiments, about 10 percent to about 50 percent of the original (unflattened) thickness of the overlying composite filament is melted. In other words, in some embodiments, up to about one-half of the composite fiber (the lower half) is melted.

[0042] It is very difficult or impossible to exercise the precise control over temperature profiles that is required to maintain wettability and provide the partial melting described above when using a conventional heat source (e.g., a conductive heating element, directed hot air, etc.). Hence, in the illustrative embodiment, focused heat source 206 is used to provide precisely controlled heating of a just-deposited composite filament as well as an underlying composite filament.

[0043] In some alternative embodiments, other focused heated sources may suitably be used, such as, without limitation, a concentrated microwave source (MASER), focused ultrasonic sound, focused infrared radiation, ion beam, and electron beam.

[0044] Shaper 210 applies “downward-directed” pressure to the softened/partially melted filament, thereby controlling its position/location and altering its cross section from substantially circular to a flattened form. As used in this disclosure and the appended claims, the term “flattened” means that the width of the composite fiber is at least 5 times greater than its thickness. Furthermore, the term “flattened” includes cross sections that are not literally “flat-rectangular,” including, without limitation, plano-convex, plano-concave, bi-concave, and meniscus. Such not-literally-rectangular forms may result, for example, from the shape of an underlying build surface. As previously mentioned, alteration of the cross section in the aforementioned fashion facilitates consolidation of the composite filament into the geometry of the desired object.

[0045] FIG. 3 depicts deposition system 200′ in accordance with an illustrative embodiment of invention. System 200′ is an implementation of system 200 depicted in FIG. 2.

[0046] In system 200′, positioning subsystem 202 is embodied as notional robotic arm 302. The robotic arm is coupled to support plate 318, which supports the various subsystems and elements of system 200′. Robotic arm 302 moves support plate 318, and all subsystems/elements attached thereto, so as to position the system to deliver a composite filament to a desired point in space consistent with the build instructions for the part.

[0047] In the illustrative embodiment, robotic arm 302 is appropriately configured with rigid members 314 and joints 316 to provide six degrees of freedom (three in translation: x, y, and z axes; and three in orientation: pitch, yaw, and roll).

[0048] In system 200′, feed subsystem 204 includes spool 320, feed motor 326, feed tube 328, and cutter 330. Spool 320 is rotatably coupled to member 322, the latter of which is attached (e.g., via bolts 324, etc.) to support plate 318. Composite filament 336 is wound around spool 320. The filament passes through motor 326, feed tube 328, and cutter 330. Motor 326 draws composite filament 336 from spool 320. As it passes through cutter 330, filament 336 is sized, as appropriate, in accordance with build instructions. Feed tube 328 is attached to support plate 318, such as via clamps 334.

[0049] Filament 336 is delivered to build plate 350 from delivery end 332 of feed tube 328. It will be appreciated that if manufacture of a part has already begun, filament 336 might be delivered to a previously deposited layer of composite filament. The term “build surface,” as used in this disclosure and the appended claims, refers to either a build plate, etc., such as build plate 350, or a previously deposited layer of material, or anything else that filament 336 might be deposited upon.

[0050] In the illustrative embodiment, feed tube 328 is used to simply deliver and guide filament, in its original form (i.e., no change in shape, etc.) to the build plate 350. In some embodiments, feed tube 328 is not heated.

[0051] In some embodiments, delivery end 332 of the feed tube 328 is appropriately configured and/or positioned to deliver the composite filament directly underneath shaper 210, which is embodied in the illustrative embodiment as roller 340.

[0052] Roller 340 rotates about pin 341 but is otherwise rigidly coupled to support plate 318 via member 342 and bolts 344. In other words, roller 340 is free to rotate about pin 341 along the x-direction, but is rigidly coupled to support plate 318 with respect to movements along the y-direction and the z-direction.

[0053] In system 200′, focused heat source 206 is embodied as laser 346, such as a diode or fiber laser, although other types of lasers may suitably be used. Laser 346 is rigidly coupled to support plate 318, such as via clamps 348.

[0054] In the illustrative embodiment, laser 346 is aligned to illuminate the portion of filament delivered to build plate 350. The laser heats the filament to softening for incorporation into the build object.

[0055] As previously noted, a laser is preferentially used as focused heat source 208 because it enables precise and accurate control of the processing temperature. Because the laser spot size can be precisely controlled, the laser can be directed to melt a previously deposited, underlying layer while simply heating the currently deposited layer until it softens. Or the laser can be directed to partially melt both the underlying and overlying layer. Again, melting the underlying layer during the deposition process results in an increase in bonding and adhesion between the layers, enhancing the overall mechanical properties of the build object.

[0056] n some other embodiments, one laser is used for softening or partially melting the just-deposited filament, while a second laser is used to at least partially melt a previously deposited layer. In some further embodiments, a focused heat source is used to melt the underlying filament, but a heat source other than a laser (not necessarily a focused heat source; for example, a hot air blower, etc.) is used to soften the filament being deposited. This can occur before directly before or after the filament is deposited.

[0057] Robotic arm 302 positions support plate 318 such that roper 340 applies pressure to the deposited filament. The applied pressure ensures that the filament sticks and adheres to the underlying layer. In the absence of such pressure, only gravity is available to bond and adhere the filament to the underlying layer, providing a relatively weak interface.

[0058] Furthermore, as previously discussed, the applied pressure reshapes the cross section of the filament from substantially circular to a flattened form. That is, the substantially cylindrical composite filament feed is transformed into a flattened substantially tape-like form.

[0059] In the prior art, wherein gravity alone is applied during deposition, the composite filament's cross section morphs from circular/rectangular to elliptical. Elliptical-shaped filaments tend to leave gaps and interstices in the build object. These gaps and interstices can act as nucleation sites for crack propagation, negatively impacting the mechanical properties of the build part. On the other hand, the flattened form in accordance with embodiments of the invention results in parts having minimal void/interstitial space. This results in printed parts having relatively better material properties.

[0060] In illustrative embodiment, there is a 1:1 input-to-output material feed rate (i.e., the cross-sectional area of the filament entering the system equals that of the filament exiting the system to create the build object). Thus, although the cross-sectional shape of the composite filament changes in accordance with the present teachings (i.e., it is flattened), the cross-section area of the filament does not change.

[0061] FIG. 4 depicts method 400 for additive manufacturing. In accordance with operation S401, a filament is deposited on the build surface or previously deposited layer of filament. In the illustrative embodiment, the filament is softened or partially melted, per operation S402. In the illustrative embodiment, the filament is softened after deposition; however, in some alternative embodiments, the filament is softened immediately prior to deposition.

[0062] The important point here is that the composite filament must retain the ability to be shapeable (i.e., re-shaped to a flattened form of desired width and/or thickness). It is notable that a liquid will take the shape of a vessel, etc., into which it is poured. That is not a contemplated embodiment; in embodiments of the invention, the composite filament retains form/shape without external constraints.

[0063] In operation S403, at least a portion of the filament underlying the most recently deposited filament is melted. Per operation S404, the feed composite filament, which typically has a substantially circular cross section, is reshaped to a flattened form having a tape-like aspect ratio. As previously noted, the width of the reshaped composite filament is at least 5 times greater than its thickness. In the illustrative embodiment, reshaping is accomplished via applied pressure; that is, by compressing the composite filament.

[0064] In some embodiments, operations S402 and S403 are performed concurrently. In some other embodiments, operation S402 is performed before operation S403. In some embodiments, operations S402, S403, and S404 are performed concurrently.

[0065] It is to be understood that although this disclosure teaches many examples of embodiments in accordance with the present teachings, many additional variations of the invention can easily be devised by those skilled in the art after reading this disclosure. As a consequence, the scope of the present invention is to be determined by the following claims.