Patent · US9776376B2 · B2 · US

Methods and apparatus for three-dimensional printed composites based on flattened substrate sheets

(11) Publication number

US9776376B2

(21) Application number

14/703,372

(22) Filing date

2015-05-04

(30) Priority date

2011-08-29

(43) Publication date

2017-10-03

(45) Date of grant

2017-10-03

(52) CPC

B32B Layered products, i.e. products built-up of strata of flat or non-flat, e.g. cellular or honeycomb, form: 5/26, 1/00, 2260/021, 2260/023, 2260/04, 2260/046, 2262/106, 5/022, 5/024, 7/14
B29C Shaping or joining of plastics; shaping of material in a plastic state, not otherwise provided for; after-treatment of the shaped products, e.g. repairing: 64/141, 64/147, 64/153, 67/0074, 67/0077, 70/22
B29L Indexing scheme associated with subclass B29C, relating to particular articles: 2009/00
B33Y Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering: 70/00
G03G Electrography; electrophotography; magnetography: 15/224, 15/225
Y10T Technical subjects covered by former us classification: 428/24479, 428/2481, 428/24826, 428/24843, 442/60, 442/67

(73) Assignee

IMPOSSIBLE OBJECTS LLC

(54) Title

Methods and apparatus for three-dimensional printed composites based on flattened substrate sheets

(57) Abstract

A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

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Claims (18)

A method of fabricating a three-dimensional (3D) object, comprising: pre-processing each of a plurality of substrate sheets to reduce planar inconsistencies or imperfections, wherein a sheet corresponds to a layer of the 3D object; selectively depositing an adhering agent in a desired pattern onto portions of a pre-processed layer of substrate material for each layer; applying powder on areas of each of the plurality of substrate layers corresponding to both where the adhering agent is selectively deposited and where it is not; removing loose powder; stacking the substrate layers in a predetermined order for creating the three dimensional (“3D”) object; transforming at least some of the powder into a substance that flows and subsequently hardens into hardened material, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of substrate layers; and removing at least some of negative regions from the stacked substrate layers to form the 3D object, the 3D object comprising the portions of the stacked plurality of substrate layers that are infiltrated or coated by and bound together by the hardened material.
The method of claim 1, wherein the removing is performed at least in part by mechanical abrasion.
The method of claim 1, wherein the plurality of substrate layers comprise carbon fiber.
The method of claim 1, wherein the pre-processing comprises flattening with the application of heat, pressure, tension, or a combination thereof, to each of the plurality of substrate layers.
The method of claim 1, wherein the pre-processing comprises processing the plurality of substrate layers such that the planar inconsistencies or imperfections of each layer are reduced so as not to exceed a defined range of variation above or below a target dimension based on an initial design specification of the 3D object.
The method of claim 1, wherein the transforming comprises melting at least part of the powder.
The method of claim 1, wherein the transforming comprises a chemical reaction.
The method of claim 1, wherein the removal of loose powder consists of removing the powder from the portion of the substrate layer to which the adhering agent was not applied.
The method of claim 1, wherein at least one of the plurality of substrate layers is treated with a material that modifies the surface energy of the substrate layer.
The method of claim 1, wherein the planar inconsistencies or imperfections comprise local waviness, crimping, wrinkling, or a combination thereof.
A method of fabricating a three-dimensional (3D) object, comprising: flattening a plurality of substrate sheets, wherein a sheet corresponds to a layer of the 3D object; selectively depositing an adhering agent in a desired pattern onto portions of a pre-processed layer of substrate material for each layer; applying powder on areas of each of the plurality of substrate layers corresponding to both where the adhering agent is selectively deposited and where it is not; removing loose powder; stacking the substrate layers in a predetermined order for creating the 3D object; transforming at least some of the powder into a substance that flows and subsequently hardens into hardened material, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of substrate layers; and removing at least some of the negative regions from the stacked substrate layers to form the 3D object, the 3D object comprising the portions of the stacked plurality of substrate layers that are infiltrated or coated by and bound together by the hardened material.
The method of claim 11, wherein the removing is performed at least in part by mechanical abrasion.
The method of claim 11, wherein the plurality of substrate layers comprise carbon fiber and the flattening comprises an application of heat to the carbon fiber substrate layers.
The method of claim 13, wherein the flattening further comprises an application of pressure and/or tension to the carbon fiber substrate layers.
The method of claim 11, wherein the flattening comprises processing the plurality of substrate layers such that a flatness of each of the plurality of substrate layers is within a defined range of variation above or below a target dimension based on an initial design specification of the 3D object.
A method of fabricating a three-dimensional (3D) object, comprising: pre-processing each of a plurality of substrate sheets to reduce planar inconsistencies or imperfections, wherein a sheet corresponds to a layer of the 3D object; selectively depositing an adhering agent in a desired pattern onto portions of a pre-processed layer of substrate material for each layer; applying powder on areas of each of the plurality of substrate layers corresponding to both where the adhering agent is selectively deposited and where it is not; removing loose powder; and stacking the substrate layers in a predetermined order for creating the 3D object.
The method of claim 16, comprising: transforming at least some of the powder into a substance that flows and subsequently hardens into hardened material, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of substrate layers.
The substrate of claim 16, wherein sheet flatness is achieved through the application of heat and/or pressure and/or tension to the substrate.

Citations (58)

CN101181776A
CN104150915A
CN201329424Y
EP2776233A2
EP2961585A2
JPH11236541A
US2002104935A1
US2004070582A1
US2004112523A1
US2005059757A1
US2006061618A1
US2007241482A1
US2008006958A1
US2008260954A1
US2009255428A1
US2009321979A1
US2010302326A1
US2011045724A1
US2011101564A1
US2011121491A1
US2013171431A1
US2014238173A1
US2014257549A1
US2015137423A1
US2015158246A1
US2015231825A1
US2016082657A1
US2016082658A1
US2016082695A1
US2016339645A1
US3431166A
US4312268A
US4393389A
US4453694A
US4863538A
US5176949A
US5204055A
US5260009A
US5340656A
US5364657A
US5369192A
US5514232A
US5637175A
US5876550A
US5988959A
US6147138A
US6161995A
US6471800B2
US6551038B1
US6596224B1
US6632054B2
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US6780368B2
US8377547B2
WO2007114895A2
WO2013010108A1
WO2013033273A2
WO2014134224A2

Record as JSON

{
  "publication_number": "US9776376B2",
  "country": "US",
  "kind": "B2",
  "title": "Methods and apparatus for three-dimensional printed composites based on flattened substrate sheets",
  "abstract": "A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.",
  "claims": [
    "1. A method of fabricating a three-dimensional (3D) object, comprising: pre-processing each of a plurality of substrate sheets to reduce planar inconsistencies or imperfections, wherein a sheet corresponds to a layer of the 3D object; selectively depositing an adhering agent in a desired pattern onto portions of a pre-processed layer of substrate material for each layer; applying powder on areas of each of the plurality of substrate layers corresponding to both where the adhering agent is selectively deposited and where it is not; removing loose powder; stacking the substrate layers in a predetermined order for creating the three dimensional (“3D”) object; transforming at least some of the powder into a substance that flows and subsequently hardens into hardened material, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of substrate layers; and removing at least some of negative regions from the stacked substrate layers to form the 3D object, the 3D object comprising the portions of the stacked plurality of substrate layers that are infiltrated or coated by and bound together by the hardened material.",
    "2. The method of claim 1, wherein the removing is performed at least in part by mechanical abrasion.",
    "3. The method of claim 1, wherein the plurality of substrate layers comprise carbon fiber.",
    "4. The method of claim 1, wherein the pre-processing comprises flattening with the application of heat, pressure, tension, or a combination thereof, to each of the plurality of substrate layers.",
    "5. The method of claim 1, wherein the pre-processing comprises processing the plurality of substrate layers such that the planar inconsistencies or imperfections of each layer are reduced so as not to exceed a defined range of variation above or below a target dimension based on an initial design specification of the 3D object.",
    "6. The method of claim 1, wherein the transforming comprises melting at least part of the powder.",
    "7. The method of claim 1, wherein the transforming comprises a chemical reaction.",
    "8. The method of claim 1, wherein the removal of loose powder consists of removing the powder from the portion of the substrate layer to which the adhering agent was not applied.",
    "9. The method of claim 1, wherein at least one of the plurality of substrate layers is treated with a material that modifies the surface energy of the substrate layer.",
    "10. The method of claim 1, wherein the planar inconsistencies or imperfections comprise local waviness, crimping, wrinkling, or a combination thereof.",
    "11. A method of fabricating a three-dimensional (3D) object, comprising: flattening a plurality of substrate sheets, wherein a sheet corresponds to a layer of the 3D object; selectively depositing an adhering agent in a desired pattern onto portions of a pre-processed layer of substrate material for each layer; applying powder on areas of each of the plurality of substrate layers corresponding to both where the adhering agent is selectively deposited and where it is not; removing loose powder; stacking the substrate layers in a predetermined order for creating the 3D object; transforming at least some of the powder into a substance that flows and subsequently hardens into hardened material, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of substrate layers; and removing at least some of the negative regions from the stacked substrate layers to form the 3D object, the 3D object comprising the portions of the stacked plurality of substrate layers that are infiltrated or coated by and bound together by the hardened material.",
    "12. The method of claim 11, wherein the removing is performed at least in part by mechanical abrasion.",
    "13. The method of claim 11, wherein the plurality of substrate layers comprise carbon fiber and the flattening comprises an application of heat to the carbon fiber substrate layers.",
    "14. The method of claim 13, wherein the flattening further comprises an application of pressure and/or tension to the carbon fiber substrate layers.",
    "15. The method of claim 11, wherein the flattening comprises processing the plurality of substrate layers such that a flatness of each of the plurality of substrate layers is within a defined range of variation above or below a target dimension based on an initial design specification of the 3D object.",
    "16. A method of fabricating a three-dimensional (3D) object, comprising: pre-processing each of a plurality of substrate sheets to reduce planar inconsistencies or imperfections, wherein a sheet corresponds to a layer of the 3D object; selectively depositing an adhering agent in a desired pattern onto portions of a pre-processed layer of substrate material for each layer; applying powder on areas of each of the plurality of substrate layers corresponding to both where the adhering agent is selectively deposited and where it is not; removing loose powder; and stacking the substrate layers in a predetermined order for creating the 3D object.",
    "17. The method of claim 16, comprising: transforming at least some of the powder into a substance that flows and subsequently hardens into hardened material, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of substrate layers.",
    "18. The substrate of claim 16, wherein sheet flatness is achieved through the application of heat and/or pressure and/or tension to the substrate."
  ],
  "cpc": [
    "B32B 5/26",
    "B29C 64/141",
    "B29C 64/147",
    "B29C 64/153",
    "B29C 67/0074",
    "B29C 67/0077",
    "B29C 70/22",
    "B29L 2009/00",
    "B32B 1/00",
    "B32B 2260/021",
    "B32B 2260/023",
    "B32B 2260/04",
    "B32B 2260/046",
    "B32B 2262/106",
    "B32B 5/022",
    "B32B 5/024",
    "B32B 7/14",
    "B33Y 70/00",
    "G03G 15/224",
    "G03G 15/225",
    "Y10T 428/24479",
    "Y10T 428/2481",
    "Y10T 428/24826",
    "Y10T 428/24843",
    "Y10T 442/60",
    "Y10T 442/67"
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  "assignees": [
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  "filing_date": "2015-05-04",
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  "priority_date": "2011-08-29",
  "application_number": "US-201514703372-A",
  "family_id": "53799618",
  "citations": [
    "CN101181776A",
    "CN104150915A",
    "CN201329424Y",
    "EP2776233A2",
    "EP2961585A2",
    "JPH11236541A",
    "US2002104935A1",
    "US2004070582A1",
    "US2004112523A1",
    "US2005059757A1",
    "US2006061618A1",
    "US2007241482A1",
    "US2008006958A1",
    "US2008260954A1",
    "US2009255428A1",
    "US2009321979A1",
    "US2010302326A1",
    "US2011045724A1",
    "US2011101564A1",
    "US2011121491A1",
    "US2013171431A1",
    "US2014238173A1",
    "US2014257549A1",
    "US2015137423A1",
    "US2015158246A1",
    "US2015231825A1",
    "US2016082657A1",
    "US2016082658A1",
    "US2016082695A1",
    "US2016339645A1",
    "US3431166A",
    "US4312268A",
    "US4393389A",
    "US4453694A",
    "US4863538A",
    "US5176949A",
    "US5204055A",
    "US5260009A",
    "US5340656A",
    "US5364657A",
    "US5369192A",
    "US5514232A",
    "US5637175A",
    "US5876550A",
    "US5988959A",
    "US6147138A",
    "US6161995A",
    "US6471800B2",
    "US6551038B1",
    "US6596224B1",
    "US6632054B2",
    "US6740185B2",
    "US6780368B2",
    "US8377547B2",
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    "WO2013010108A1",
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  ]
}

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