Systems and methods for additively manufacturing high strength and stiffness fiber-reinforced inorganic glass composite structures

1 . A feedstock for performing additive manufacturing through a heated extrusion print nozzle heated to a working printing temperature, the feedstock comprising:

a glass matrix flowable through the heated extrusion print nozzle, and meltable at the working printing temperature to enable leaving the heated extrusion print nozzle as a flowable bead onto a build plate; and

a reinforcing fiber component disposed within the glass matrix, selected to be at least one of thermally stable or thermally oxidatively stable at the working printing temperature being used to melt the glass matrix; and

wherein the reinforcing fiber component is of a volume fraction such that during an extrusion operation the reinforcing fiber component is constrained within the glass matrix and preferentially aligns in a direction of extrusion while forming a structure on a build plate; and

wherein the reinforcing fiber component comprises at least one of a tape of one or more continuous reinforcing fibers, a tow of one or more continuous reinforcing fibers, a braid of continuous reinforcing fibers, or a combination of two or more of continuous tape, tow, and braid reinforcing fibers.

2 . The feedstock of claim 1 , wherein the glass matrix comprises glass powder which is at least one of stabilized or partially consolidated with a quantity of organic binder in a range of between 3.0%-20% by volume.

3 . The feedstock of claim 2 , wherein the binder is reactive to at least one of temperature or UV light to enable gelation of the structure on printing.

4 . The feedstock of claim 2 , wherein the binder at least one of burns out or condenses to form at least one of additional glass or ceramic-phase during thermal post-processing operations.

5 . The feedstock of claim 1 , wherein the glass matrix comprises an inorganic silica-based glass composition including at least one of:

soda-lime glass; or

borosilicate glass including at least one of e-glass, s-glass, m-glass or pure quartz glass.

6 . The feedstock of claim 1 , wherein the glass matrix comprises a glass matrix which has been toughened by an ion exchange process.

7 . The feedstock of claim 1 , wherein the glass matrix comprises glass powder at least one of stabilized or partially consolidated with polyolefin.

8 . The feedstock of claim 1 , wherein the glass matrix comprises glass powder at least one of stabilized or partially consolidated with sodium metasilicate.

9 . The feedstock of claim 1 , wherein the glass matrix includes at least one of:

a flowing agent to enhance flow; or

an anti-clumping agent.

10 . The feedstock of claim 1 , wherein:

the glass matrix includes at least one of nano filler additives or micro filler additives; and

wherein the at least one of nano filler additives or micro filler additives includes at least one of:

SiC nanowhiskers;

BN nanofibers;

ceramic hollow spheres; or

diamond grit microparticles.

11 . The feedstock of claim 1 , wherein a fiber volume fraction comprises between 0 and 60% by volume of the feedstock.

12 . A system for additive manufacturing, comprising:

at least one of a computer or electronic controller;

a memory in communication with the computer/electronic controller for storing code in accordance with a 3D part design file needed to build a part in a layer-by-layer fashion;

a reservoir;

a feedstock including:

a quantity of a flowable glass matrix in one of a powdered form, a slurry or a paste, contained in the reservoir; and

a reinforcing fiber component at least one of mixed in with, or entrained in, the quantity of flowable glass matrix;

the reinforcing fiber component comprising at least one of a tape of continuous reinforcing fiber or fibers, a tow of continuous reinforcing fibers or fiber, a braid of continuous reinforcing fibers, or a combination of two or more of tape, tow and braid continuous reinforcing fibers;

a print nozzle;

a heater configured to heat the print nozzle and the feedstock, such that the feedstock is heated to a working temperature sufficient to melt the glass matrix and form a melted feedstock mixture, and wherein the reinforcing fiber component is thermally stable at the working temperature;

the print nozzle configured to receive the melted feedstock mixture of flowable glass matrix with the reinforcing fiber component and to extrude a bead of melted feedstock onto at least one of a substrate or build plate in accordance with the code;

a nozzle diameter and taper of the print nozzle is such that the reinforcing fiber component aligns in the extruded bead from the print nozzle in a direction of extrusion;

a motion control subsystem configured to move at least one of the print nozzle, the substrate or the build plate as needed to lay a plurality of the beads of melted feedstock down to form each layer of the part in a layer-by-layer fashion.

13 . The system of claim 12 , further comprising a ram for forcing the feedstock into the print nozzle.

14 . A system for additive manufacturing, comprising:

at least one of a computer or electronic controller;

a memory in communication with the computer/electronic controller for storing code in accordance with a 3D part design file needed to build a part in a layer-by-layer fashion;

a feedstock including a consolidated filament of glass and a fiber reinforcing component;

the fiber reinforcing component comprising at least one of a tape of continuous reinforcing fiber or fibers, a tow of continuous reinforcing fibers or fiber,

a braid of continuous reinforcing fibers, or a combination of two or more of tape, tow and braid continuous reinforcing fibers;

a support component for supporting the feedstock in a manner such that the feedstock can be withdrawn from the support component;

a print nozzle;

a heater for heating the print nozzle and the feedstock, such that the feedstock is heated to a working temperature sufficient to melt the consolidated filament of glass as the feedstock passes through the print nozzle to form a flowable glass matrix bead, and wherein the fiber reinforcing component is stable at the working temperature;

the print nozzle configured to receive the flowable glass matrix bead with the fiber reinforcing component mixed therein and to extrude the flowable glass matrix bead of melted feedstock onto at least one of a substrate or build plate in accordance with the code;

a motion control subsystem for moving at least one of the print nozzle, the substrate or the build plate as needed to form each layer of the part in a layer-by-layer fashion; and

a light source to at least partially cure the flowable glass matrix bead as the flowable glass matrix bead is deposited on the at least one of a substrate or build plate.