Methods for fiber reinforced additive manufacturing
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.
1. A three-dimensional printer for additive manufacturing of a part, comprising:
a build plate configured to support the part;
a tray configured to contain a photopolymer resin;
a printhead including a nozzle configured to deposit a continuous or semi-continuous core filament within a layer of the photopolymer resin;
a motorized feeding mechanism configured to drive the continuous or semi-continuous core filament through the nozzle;
a motorized printhead transport mechanism configured to relatively move the printhead and the build plate;
a source of electromagnetic radiation configured to generate electromagnetic radiation;
a controllable mirror configured to direct the electromagnetic radiation generated by the source of electromagnetic radiation; and
a controller operatively connected to the controllable mirror and configured to control the controllable mirror to direct the electromagnetic radiation to a desired location in the layer of photopolymer resin containing the deposited continuous or semi-continuous core filament.
2. The three-dimensional printer of claim 1 , wherein the tray is further configured to contain the photopolymer resin in a liquid or powder form.
3. The three-dimensional printer of claim 1 , wherein the electromagnetic radiation generated by the source of electromagnetic radiation is one of laser and ultraviolet light.
4. The three-dimensional printer of claim 1 , further comprising a cutter configured to sever the continuous or semi-continuous core filament.
5. The three-dimensional printer of claim 1 , wherein the controller is further configured to control the controllable mirror to direct the electromagnetic radiation from the source of electromagnetic radiation to sever the continuous or semi-continuous core filament.
6. The three-dimensional printer of claim 1 , wherein the motorized feeding mechanism is configured to drive the continuous or semi-continuous core filament through the nozzle at a feed rate equal to the deposition rate of the continuous or semi-continuous core filament from the nozzle.