Additive manufacturing method for embedding fibers in a three-dimensional structure
A three-dimensional object printer includes at least one ejector that is operated to form an uppermost layer of photopolymer material on a substrate. The ejected uppermost photopolymer layer is partially cured and a portion of mesh sheet is positioned on the partially cured layer before the at least one eject continues to eject photopolymer material onto the uppermost layer. The portion of the mesh sheet reinforces the layers of photopolymer material and adds strength and durability to the overall part being formed with the photopolymer material.
1. An additive manufacturing method for embedding fibers in a three-dimensional structure comprising:
operating with a controller at least one ejector in a plurality of ejectors to form at least one layer of a photopolymer material on a substrate;
operating with the controller a source of ultraviolet (UV) radiation to partially cure the at least one layer of photopolymer material on the substrate;
operating with the controller an actuator to position fibers onto a top surface of the at least one layer of partially cured photopolymer material on the substrate; and
after positioning the fibers on the top surface, operating with the controller the at least one ejector to eject additional photopolymer material onto the fibers positioned on the top surface to form at least one other layer of photopolymer material on the fibers on the substrate.
2. The method of claim 1 , the positioning of the fibers further comprising:
operating the actuator with the controller to position at least one piece of mesh onto the top surface of the at least one layer of cured photopolymer.
3. The method of claim 2 further comprising:
operating with the controller a cutting device to cut the at least one piece of mesh into a shape that corresponds to a portion of the at least one layer of photopolymer material.
4. The method of claim 3 further comprising:
generating with an optical sensor image data of the at least one layer of the photopolymer material; and
generating with the controller signals for operating the cutting device and the at least one ejector with reference to the image data generated by the optical sensor.
5. The method of claim 3 further comprising:
generating with the controller signals for operating the cutting device with reference to image data used to operate the at least one ejector to form the at least one layer of photopolymer material.
6. The method of claim 3 , the operation of the cutting device further comprising:
operating with the controller a laser to cut the at least one piece of mesh.
7. The method of claim 3 , the operation of the cutting device further comprising:
operating with the controller a blade to cut the at least one piece of mesh.
8. The method of claim 1 further comprising:
operating with the controller a second actuator to press a plate or a roller into the at least one other layer and the at least one piece of mesh material to level a top surface of the at least one other layer and the at least one piece of mesh material.
9. The method of claim 1 further comprising:
operating a leveler with the controller to remove a portion of the at least one other layer of the photopolymer material.
10. The method of claim 2 , the operation of the actuator further comprising:
operating a robotic arm with the controller to move the at least one piece of mesh.
11. The method of claim 10 , the operation of the robotic arm further comprising:
operating the robotic arm with the controller to orient a first piece of mesh in a first orientation before positioning the first piece of mesh on the top surface of the partially cured photopolymer; and
operating the robotic arm with the controller to orient a second piece of mesh in a second orientation that is different than the first orientation before positioning the second piece of mesh on the top surface of the partially cured photopolymer.
12. The method of claim 1 , the positioning of the fibers further comprising:
operating the actuator with the controller to dispense fibers from a nozzle onto the top surface of the partially cured photopolymer material.
13. An additive manufacturing method for embedding a portion of a mesh sheet in a three-dimensional structure comprising:
operating at least one ejector in a plurality of ejectors to form an uppermost layer of a photopolymer material supported by a substrate;
operating a cutting device to cut at least one portion from a mesh sheet;
operating a first actuator to position the at least one portion cut from the mesh sheet on a top surface of the uppermost layer of the ejected photopolymer material supported by the substrate; and
operating the at least one ejector to eject additional photopolymer material onto the at least one portion from the mesh sheet to form at least one other layer of photopolymer material on the at least one portion from the mesh sheet.
14. The method of claim 13 further comprising:
operating a source of ultraviolet (UV) radiation to cure the at least one layer of photopolymer partially before operating the first actuator to position the at least one portion cut from the mesh sheet onto the top surface of the uppermost layer.
15. The method of claim 13 further comprising:
generating with an optical sensor image data of the uppermost layer of the ejected photopolymer material; and
generating signals for operating the cutting device and the at least one ejector with reference to the image data generated by the optical sensor.
16. The method of claim 15 , the operation of the cutting device further comprising:
operating a laser to cut the at least one portion from the mesh sheet.
17. The method of claim 15 , the operation of the cutting device further comprising:
operating a blade to cut the at least one portion of the mesh sheet.
18. The method of claim 13 further comprising:
operating a second actuator to press a plate or a roller into the uppermost layer and the at least one portion of mesh material to level the top surface of the uppermost layer and the at least one portion of the mesh sheet.
19. The method of claim 13 , the operation of the actuator further comprising:
operating a robotic arm to move the at least one portion of the mesh sheet.
20. The method of claim 19 , the operation of the robotic arm further comprising:
operating the cutting device to cut another portion from the mesh sheet; and
operating the robotic arm to orient the other portion of the mesh sheet in an orientation that is different than an orientation of the at least one portion cut from the mesh sheet.