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A process and apparatus for making three-dimensional, composite material objects of a predetermined shape by sequentially depositing multiple layers of continuous reinforcement fibers and solidifying matrix material on a base member in a desired pattern. The apparatus comprises (a) a movable nozzle

A process and apparatus for making three-dimensional, composite material objects of a predetermined shape by sequentially depositing multiple layers of continuous reinforcement fibers and solidifying matrix material on a base member in a desired pattern. The apparatus comprises (a) a movable nozzle having a flow passage and a dispensing outlet, (b) a supply of reinforcement fibers and a matrix material, a mixing device for impregnating the fibers with a matrix material to form a preimpregnated tow, and a heating device for introducing the matrix material in a fluid state, (c) a base member to support the object being made, (d) mechanical movement devices for moving the base member relative to the movable nozzle in a predetermined sequence and pattern, and for displacing the movable nozzle a predetermined incremental distance relative to the base member and relative to each successive layer deposited prior to the start of the formation of each successive layer to form multiple layers of composite material of a predetermined thickness, and (e) a metering device for discharging the preimpregnated tow at a predetermined rate onto the base member. The apparatus preferably further comprises (f) a computer-aided design computer and supporting software programs that are capable of creating a three-dimensional drawing of a desired object and converting the drawing into multiple elevation layer data, and (g) a three-dimensional motion controller electronically linked to the mechanical movement devices and operative to actuate these movement devices in response to the drive signals received from the computer.

대표청구항 ▼

[ What is claimed is:] [1.] Apparatus for making three-dimensional, composite material-based objects of a predetermined shape by sequentially depositing multiple layers of continuous reinforcement fibers and solidifying matrix material on a base member in a desired pattern, comprising:(a) a movable

[ What is claimed is:] [1.] Apparatus for making three-dimensional, composite material-based objects of a predetermined shape by sequentially depositing multiple layers of continuous reinforcement fibers and solidifying matrix material on a base member in a desired pattern, comprising:(a) a movable head having flow-passage means therein connected to a dispensing outlet at one end thereof, said outlet comprising a tip with a discharge orifice of predetermined size therein;(b) a supply of reinforcement fibers and a matrix material, means for mixing said reinforcement fibers and matrix material to form a continuous preimpregnated tow, and means for introducing said reinforcement fibers and matrix material into said flow-passage means so that said matrix material is in a fluid state;(c) a base member located in the close, working vicinity of said dispensing outlet of said movable head;(d) mechanical means for moving said base member relative to said movable head in three dimensions along "X," "Y," and "Z" axes in a rectangular coordinate system in a predetermined sequence and pattern, and for displacing said movable head a predetermined incremental distance relative to said base member and thence relative to each successive layer deposited prior to the start of the formation of each successive layer to form multiple layers of said reinforcement fibers and matrix material of predetermined thickness which build up on each other sequentially as said matrix material solidifies after discharge from said orifice; and(e) means for metering the discharge of said reinforcement fibers and matrix material from said discharge orifice at a predetermined rate onto said base member to form a three-dimensional object as said base member and said movable head are moved relative to each other.