Description
The present invention relates to a device for continuous extrusionbased fibre additive manufacturing. The present invention further relates to a method for continuous extrusion-based fibre additive manufacturing and 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.
In order to increase the strength and stiffness of additive manufacturing, use can be made of 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. However, although 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.
In order to further improve the additive manufacturing capability, efforts have been made to provide additive manufacturing wherein a continuous fibre reinforcement is embedded into a base polymer material and wherein the continuous fibre additive is extruded from an extrusion nozzle.
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. It was found that by providing 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. It was found that by providing the device of the present invention, 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. In a preferred embodiment, 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. Even further preferred 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. In a more preferred embodiment of the present invention, the fibre outlet of the fibre feed system slightly extends from the extrusion outlet.
The fibre feed system may be connected to a vacuum unit for applying a vacuum to the fibre feed system. By application of 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.
In order to provide the optimal continuous fibre additives characteristics, 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. Preferably the inner diameter of the fibre feed system is chosen such that the diameter is larger than the maximum outer diameter 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. Typically, the drive means of a fibre feed system comprises two cooperating rotating drives. However, it is noted that 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. By providing granules of a base polymer material, 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 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;
b) feeding the fibre material to a fibre feed system and feeding the base polymer material to a base polymer material inlet of an extrusion chamber; and
c) extruding the fibre material from a fibre outlet of the fibre feed system and extruding the base polymer material from an extrusion outlet of the extrusion chamber to form a continuous fibre additive, wherein the extruded continuous fibre additive is formed after the base polymer material is extruded from the extrusion outlet of the extrusion chamber. By formation of the continuous fibre additive downstream the extrusion outlet of the extrusion chamber, clogging of the extrusion outlet is herewith prevented. As a result, the method of the present invention provides in 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.
In a preferred embodiment 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.
In a further embodiment of the present invention the method comprises the step of applying a vacuum to the fibre feed system. Preferably the vacuum is applied to the fibre feed system during performance of all the steps of the method of the present invention. By providing 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.
Given the increased strength and stiffness characteristics of the continuous fibre additive produced by the method of the present invention, the present invention further relates to a continuous fibre additive obtainable by the method of the present invention wherein the method comprises applying a vacuum to the fibre feed system.
It is noted that 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. Preferably, the fibre material comprises impregnated fibre materials, i.e. a fibre material (filaments) pretreated with a polymer material, preferably the same base polymer material of the present invention. Alternatively, the fibre material may comprise a metal wire (e.g. a wire rope or may comprise glass fibre. In particular the use of a glass fibre as fibre material is preferred in order to provide further (sensing) technology into the fibre additive. For example, 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. Such 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, ULTEM™ 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.
The invention is further elucidated on the basis of the non-limitative exemplary embodiment shown in the following figure. Herein:
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. In figure 1, fibre outlet 9 slightly extends from extrusion outlet 5.
Further shown in figure 1 is 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.