Print Head for the Additive Production of Fibre Composite Materials

Simple SummaryContent extracted from patent full text and abstract with AI.

This invention presents an advanced print head for additive manufacturing (3D printing) of fiber-reinforced composite materials, such as carbon or glass fibers embedded in a polymer matrix. The print head features an infiltration unit where dry fiber bundles (rovings) are directly impregnated with molten polymer inside the 3D printer, using carefully designed deflection elements that force the polymer to deeply infiltrate the fiber bundles. This approach overcomes limitations of conventional composite filament printing by allowing on-the-fly mixing of various fibers and polymers for custom, high-performance composite parts with optimal mechanical properties.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of lightweight and high-strength parts for aerospace and automotive industries.
• Custom manufacturing of prosthetics and orthotic devices tailored for individual patients in the medical field.
• Rapid prototyping and low-volume manufacture of mechanically demanding components in machine engineering and robotics.
• Creation of sports equipment, drones, or other products requiring strong but lightweight composites.
• Production of prepregs and organosheets for subsequent forming steps.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables stronger fiber-matrix bonding and better mechanical properties than traditional composite 3D printing.
• Allows flexibility in the choice and combination of polymer matrices and reinforcing fibers, adaptable for various applications.
• Permits processing of thicker fiber bundles and variable fiber content, broadening design and performance possibilities.
• Facilitates economic, automated, and digital manufacturing of single or complex composite parts, even in batch sizes as low as one.
• Reduces material waste compared to subtractive methods and increases sustainability, especially with expensive fibers like carbon.
• Supports multimaterial printing and customized reinforcement patterns for optimized function and weight.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a print head for the additive production of a fibre composite material comprising a fibre reinforcement in a polymer matrix, comprising an infiltration unit for a mixture and/or infiltration of a fibre roving with a molten polymer; at least one feed for a polymer and/or a fibre roving into the infiltration unit; a heating element for at least partially melting the polymer within the infiltration unit; at least one deflector element within the infiltration unit and an outlet for the fibre composite material produced out of the infiltration unit, wherein the molten polymer can be directed in the infiltration unit with a polymer flow direction from the feed to the outlet along a channel between the feed and the outlet and the fibre roving can be guided within the channel from the feed to the outlet by deflection around the deflection element in parts transverse to the polymer flow direction. The invention also relates to the use of a print head for additive production, a method for additive production and a fibre composite material produced by the print head.