Method of forming a carbon fiber layup
A manufactured component, method and apparatus for advanced manufacturing that includes a polymeric working material formed into a mandrel with a carbon fiber overlay formed in a continuation of the process. The mandrel build and the carbon fiber overlay of the component preferably take place at atmospheric temperatures.
1. A method of forming a carbon fiber layup in a fused deposition modeling build comprising:
providing a supply of thermoplastic working material to a nozzle;
depositing the thermoplastic working material through the nozzle to form a mandrel within a work area, wherein the build occurs within an unheated work area;
maintaining a position of the mandrel within the work area;
applying carbon fiber over the mandrel to form a carbon fiber layup; and
removing the mandrel from the carbon fiber layup.
2. The method of claim 1 wherein the build occurs entirely within a gantry.
3. The method of claim 1 further comprising heating the thermoplastic working material with a heating element positioned with respect to the nozzle.
4. The method of claim 3 wherein the heating element comprises a coil positioned around the nozzle.
5. The method of claim 1 wherein the thermoplastic working material is provided in pelletized form.
6. The method of claim 1 wherein the thermoplastic working material is provided in a filament.
7. The method of claim 1 wherein the nozzle moves through three axes of travel within the gantry.
8. A process for manufacturing a component using fused deposition modeling comprising the steps of:
directing a desired flow of a thermoplastic working material onto a work surface within a gantry;
forming a mandrel with the thermoplastic working material;
directing a carbon fiber layup over the mandrel within the gantry;
building up the mandrel and the carbon fiber layup at atmospheric temperature; and
removing the mandrel to form the component.
9. A process for manufacturing a component using fused deposition modeling comprising the steps of:
directing a desired flow of a working material onto a work surface within a gantry, wherein the working material comprises at least one of ABS, polycarbonate, PLA, Ultem, Nylon, and PPSF/PPSU;
forming a mandrel with the working material;
directing a carbon fiber layup over the mandrel within the gantry;
building up the mandrel and the carbon fiber layup at an atmospheric temperature between 10 and 30° C.; and
removing the mandrel to form the component.
10. The process of claim 8 wherein the working material is provided in pelletized form to a nozzle, the nozzle having three axes of movement within the gantry.
11. The process of claim 8 wherein the working material is provided in a filament.
12. The process of claim 8 , wherein the working material and the carbon fiber layup are provided through a common print head.
13. The process of claim 8 wherein atmospheric temperature is between 10 and 30° C.
14. The process of claim 9 wherein the working material is provided in pelletized form to a nozzle, the nozzle having three axes of movement within the gantry.
15. The process of claim 9 wherein the working material and the carbon fiber layup are provided through a common print head.