Print Head Assembly for Additive Manufacturing with Continuous Fibres and Thermoplastic Matrix Materials for Cutting in the Hot Zone of the Print Head by Means of an Axial or Rotary Motion

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The patent describes an improved print head assembly for additive manufacturing (3D printing) of fiber-reinforced composite materials. The innovation centers on integrating a cutting unit directly inside the heated zone (hot end) of the print head, allowing fiber-reinforced filaments to be easily and efficiently cut or sheared while in a softened or molten state. The cutting can be achieved through linear or rotary motion. This design reduces the mechanical force needed to cut tough, continuous fiber composites and improves workflow for building complex printed structures.

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• Industrial 3D printers for producing high-strength, lightweight composite parts.
• Manufacture of aerospace, automotive, or sporting goods components using continuous fiber reinforcement.
• Rapid prototyping and small-batch production of custom fiber-reinforced plastic parts.
• Research and development of new composite structures requiring precise control over fiber placement and cutting within printed parts.
• Multi-material or multi-head 3D printing systems where different materials or reinforcements are needed.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly easier and more reliable cutting/shearing of tough, continuous fiber filaments due to cutting in the hot (softened) zone.
• Reduced mechanical stress and wear on the cutting mechanism, prolonging print head life and reducing maintenance needs.
• Improved accuracy and quality in the deposition and termination of fiber-reinforced paths, allowing more complex part geometries.
• Streamlined printing process and software (slicing) workflow, as the cut point is closer to the nozzle and easier to calculate, speeding up the print job.
• Capability to handle 'heavy tows' (large fiber bundles), thus enabling the printing of much stronger or thicker composite sections.
• Enables the design of compact, lightweight print heads suitable for high-speed and multi-material printing setups.
• Energy and cost efficiency due to less frequent tool changes and decreased print errors.

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Inventors & Applicants

Patent Abstract

In a first aspect, the invention relates to a print head for additively manufacturing fiber-reinforced composite materials, comprising a feed channel, a filament, a heating block, a nozzle and a cutting unit, wherein: the filament enters the nozzle through the feed channel; the nozzle has an outlet and an inlet; and the filament enters /enters the outlet of the nozzle through the feed channel, leaves the nozzle via the inlet, and is deposited on a print bed. In this process, the cutting unit is located inside the heating block. This has a beneficial effect on the cut and/or the shearing of the material to be printed. In another aspect, the invention relates to a method in which the filament is cut and/or sheared, wherein the cutting unit performs a linear movement or rotation, or the print head per se performs a linear movement or rotation, as a result of which the filament is cut and/or sheared off. In an additional aspect, the invention relates to a system comprising a plurality of print heads according to the invention.