Methods and apparatus for additive manufacturing utilizing multifunctional composite materials, and articles made therefrom
A method of depositing a multiphase material. The method includes providing a Continuous Multifunctional Composite (CMC) phase containing at least one continuous element in a polymeric matrix, passing the CMC phase through a feeding system containing a cutting system, producing a predetermined length of the CMC phase, providing a flow a molten polymer such that the molten polymer and the CMC phase are merged into a continuous co-extrusion nozzle so as to produce a co-extruded multiphase material, and depositing the co-extruded multiphase material onto a surface. An apparatus for depositing a multiphase material. The apparatus contains a co-extrusion nozzle, a means to introduce a CMC phase and a molten polymer into the co-extrusion nozzle, such that the molten polymer and the CMC phase are co-extruded and deposited on a surface. An article containing a CMC phase containing continuous elements embedded in a polymer resin forming a multiphase structure.
1. A method of depositing a multiphase material, the method comprising:
providing a CMC phase containing at least one continuous element comprising at least one material impregnated in a polymeric matrix;
passing the CMC phase containing the at least one continuous element through a feeding system containing a cutting system;
producing a predetermined length of the CMC phase containing at least one continuous element by activating the cutting system;
providing a flow a molten polymer comprising polyphenylene sulfide such that the molten polymer and the CMC phase containing at least one continuous element of predetermined length are merged into a continuous co-extrusion nozzle so as to produce a co-extruded multiphase material; and
depositing the co-extruded multiphase material onto a surface.
2. The method of claim 1 , wherein the at least one material is one of carbon fiber, glass fiber, jute fiber, and aramid fiber.
3. The method of claim 1 , wherein the at least one material is a semiconductor material.
4. The method of claim 3 , wherein the semiconductor material comprises silicon.
5. The method of claim 1 , wherein the at least one material is a metallic material.
6. The method of claim 5 , wherein the metallic material is a metal or an alloy.
7. The method of claim 6 , wherein the alloy is one of a Cr—Ni alloy, a Cr—Mo alloy, and a Cu—Ni alloy.
8. The method of claim 1 , wherein the molten polymer is made from polymer pellets using a single-screw extruder or an extrusion melt pump.
9. The method of claim 1 , wherein the molten polymer is reinforced with discontinuous fibers.
10. The method of claim 9 , wherein the fibers are one of carbon fibers, glass fibers, jute fibers, and aramid fibers.
11. The method of claim 1 , wherein the surface is a layer of a co-extruded multiphase material.
12. The method of claim 1 , wherein the polymeric matrix contains a thermosetting resin.
13. The method of claim 1 , wherein the polymeric matrix contains a thermoplastic resin and a thermosetting resin.
14. The method of claim 1 , wherein the at least one material is more than one material.
15. The method of claim 14 , wherein the more than one material is a combination of a structural material and a sensing material.
16. The method of claim 15 , wherein the structural material is one of a carbon fiber.
17. The method of claim 15 , wherein the sensing material is Cu—Ni alloy wire capable of sensing strain.
18. The method of claim 14 , wherein the more than one material is a combination of a structural material and a heating material.
19. The method of claim 18 , wherein the structural material is carbon fiber and the heating material is Ni—Cr alloy.
20. The method of claim 1 , wherein the at least one continuous element is a plurality of continuous elements.