Additive manufactured structure having a plurality of layers in a stacking direction and method for making the same
An additive manufactured structure and methods for making and using same. The structure includes a plurality of layers stacked in a stacking direction. The structure further includes at least one reinforcement structure affixed to the layers and extending at least partially in the stacking direction. The reinforcement structure can hold the layers together to stiffen and strengthen the structure. Mechanical strength of the structure in the stacking direction can advantageously be improved. Shape and spatial distribution of the reinforcement structure can be customized and adapted to the geometry of the layers to enhance strengthening effect. The reinforcement structure can be tension free or have a compressive stress induced by a preload applied during manufacturing. The compressive stress can be adjusted dynamically via a sensor. The structure and methods provide, among other things, a novel means for addressing the inherent weaknesses in parts created by large-scale extrusion deposition processes.
1. An additive-manufactured structure, comprising:
a plurality of layers stacked in a stacking direction; and
at least one reinforcement structure affixed to the layers and extending at least partially in the stacking direction, the at least one reinforcement structure extending across entire thicknesses of one or more consecutive layers of the plurality of layers.
2. The structure of claim 1 , wherein the plurality of layers defines a pocket in the stacking direction and the at least one reinforcement structure extends into the defined pocket.
3. The structure of claim 2 , wherein the defined pocket is filled with molten thermoplastic.
4. The structure of claim 1 , wherein the plurality of layers define an outer boundary in a horizontal printing direction that is substantially perpendicular to the stacking direction, and the reinforcement structure is disposed outside of the outer boundary of the plurality of layers.
5. The structure of claim 1 , wherein the plurality of layers define an outer boundary in a horizontal printing direction that is perpendicular to the stacking direction, and the reinforcement structure is disposed within the outer boundary of the plurality of layers.
6. The structure of claim 1 , further comprising a preload removably coupled to at least one end of the at least one reinforcement structure that introduces a tension in the at least one reinforcement structure.
7. The structure of claim 1 , wherein:
the at least one reinforcement structure is bonded to the plurality of the layers using at least one of a resin-based adhesive, a urethane-based adhesive, and an acrylate-based adhesive;
a selected layer of the plurality of layers comprises at least one of a carbon fiber-filled acrylonitrile butadiene styrene layer, a polyamide layer, and a co-polyester filled with carbon fibers or graphene nanofillers layer; and
the at least one reinforcement structure comprises a material selected from at least one of a polymer, a carbon composite, a glass composite, metal, ceramic, and a fabric.
8. The structure of claim 1 , further comprising a sensor removably coupled to the plurality of layers for measuring a compressive load within the plurality of layers.
9. The structure of claim 1 , wherein the at least one reinforcement structure is structurally flexible.
10. The structure of claim 1 , wherein at least one dimension of the additive-manufactured structure is greater than five feet in length.
11. The structure of claim 1 , wherein the at least one reinforcement structure extends across entire thicknesses of all of the plurality of layers.
12. A method for printing an additive-manufactured structure, the method comprising:
providing a substrate;
additively-printing a plurality of layers onto the substrate, wherein each of the additively-printed layers are printed as subsequent layers in a stacking direction; and
positioning at least one reinforcement structure that extends at least partially in the stacking direction and across entire thicknesses of one or more consecutive layers of the plurality of layers; and
affixing the at least one reinforcement structure to the plurality of the layers.
13. The method of claim 12 , further comprising applying a preload to the at least one reinforcement structure.
14. The method of claim 13 , wherein the additively-printing the plurality of layers onto the substrate creates an additive-manufactured structure that is greater than five feet in length in at least one dimension.
15. The method of claim 12 , wherein said additively-printing the plurality of layers defines a pocket extending in the stacking direction and passing through the printed layers, and wherein the at least one reinforcement structure is positioned into the defined pocket.
16. The method of claim 15 , wherein said additively-printing the plurality of layers defines the pocket by a four-way intersection of the printed layers.
17. The method of claim 12 , wherein said affixing the at least one reinforcement structure to the plurality of layers comprises applying an adhesive.
18. The method of claim 17 , wherein said affixing includes applying the adhesive prior to said positioning the at least one reinforcement structure.
19. The method of claim 12 , further comprising receiving a computer aided design file, and wherein said additively-printing the plurality of layers onto the substrate is based on the received computer aided design file.
20. The method of claim 12 , wherein the at least one reinforcement structure extends across entire thicknesses of all of the plurality of layers.