Abstract: A method and apparatus for forming a 3D article. According to the method, a composite filament material is formed from a UV curable material, a thermoset polymer material and at least one of filaments or fibers. After the composite is formed, the filament is dispensed to form the 3D article. Dispense is typically through a nozzle or other orifice that delivers the composite filament material as a bead of material. As the composite is dispensed, at least a portion of the composite material is exposed to UV radiation thereby curing a portion of the dispensed composite filament. The UV radiation is provided by a light source than can target discrete portions of the dispensed composite filament. For this purpose, the UV radiation source can be a light source integrated with the nozzle or a steered light source. As the composite filament is dispensed, UV radiation is directed onto the composite filament.

Abstract: A method and apparatus for forming a 3D article. According to the method, a composite filament material is formed from a UV curable material, a thermoset polymer material and at least one of filaments or fibers. After the composite is formed, the filament is dispensed to form the 3D article. Dispense is typically through a nozzle or other orifice that delivers the composite filament material as a bead of material. As the composite is dispensed, at least a portion of the composite material is exposed to UV radiation thereby curing a portion of the dispensed composite filament. The UV radiation is provided by a light source than can target discrete portions of the dispensed composite filament. For this purpose, the UV radiation source can be a light source integrated with the nozzle or a steered light source. As the composite filament is dispensed, UV radiation is directed onto the composite filament.

Abstract: A nozzle for dispense of a material that is a composite of fillers such as short fibers (e.g. carbon fibers) and a polymer matrix. The nozzle through which the composite material is dispensed has an expansion region through which the composite material flows. The expansion region dispenses a composite material wherein the fibers are substantially not aligned (e.g. in a random orientation with respect to each other in the polymer matrix).

Abstract: The present invention provides a system and method for the application of a functional thread to secure roving or other fibers to a substrate, thereby forming a precursor to a resultant composite component structure having targeted, enhanced structural reinforcement. The functional thread may be comprised of one or more fibrous filaments or have a monofilament structure. The invention encompasses the sewing of this functional thread at varying stitch densities as function of component stress analysis, the mechanical stresses that the component will be subject to when exposed to the forces and loads associated with its intended use, and at least one physical or mechanical property of a functional thread. This variable stitch density serves to provide targeted, localized mechanical enhancement and reinforcement to the resultant composite structure.

Abstract: Aspects of the present disclosure are directed to a three-dimensional joint and/or formation thereof, such as by 3D-printing the joint. The joint is provided with an interface region having a curable material in a curable state. The joint is positioned with the interface region in contact with a joinable member, and the interface region is cured to form a bond between the joint and the joinable member. Such an approach may, for example, involve forming a mechanical and/or chemical bond with the joint. Further, by utilizing such a joint (e.g., in a 3D-printed form), complex structural components can be formed from a curable material that can be partially cured with structures formed therein, and cured further to create the bond.

Abstract: The present invention provides an improved fiber precursor, and methods for employing such to enhance the structural reinforcement of composite structures. The precursor is comprised of one or more fibrous filaments positioned within the precursor so that the filaments within each fiber are oriented at an angle offset from the axis of the length of the precursor. The offset of these filaments can be accomplished, for example, by twisting a plurality of filaments into a continuous spiral to form the precursor, or by wrapping a collection of colinear filaments about a central core, or by braiding plurality of filaments to form the precursor. The angle of offset at which the twisted, braided or wrapped fibers are positioned can be varied as a function of the twisting, braiding or wrapping process (angle of wrap, tension upon the twisting or wrapping fibers, degree of rotational twisting applied to the fibers per length of precursor, etc.).

Abstract: The present invention provides a system and method for the application of a functional thread to secure roving or other fibers to a substrate, thereby forming a precursor to a resultant composite component structure having targeted, enhanced structural reinforcement. The functional thread may be comprised of one or more fibrous filaments or have a monofilament structure. The invention encompasses the sewing of this functional thread at varying stitch densities as function of component stress analysis, the mechanical stresses that the component will be subject to when exposed to the forces and loads associated with its intended use, and at least one physical or mechanical property of a functional thread. This variable stitch density serves to provide targeted, localized mechanical enhancement and reinforcement to the resultant composite structure.

Abstract: A method and apparatus for forming a 3D article. According to the method, a composite filament material is formed from a UV curable material, a thermoset polymer material and at least one of filaments or fibers. After the composite is formed, the filament is dispensed to form the 3D article. Dispense is typically through a nozzle or other orifice that delivers the composite filament material as a bead of material. As the composite is dispensed, at least a portion of the composite material is exposed to UV radiation thereby curing a portion of the dispensed composite filament. The UV radiation is provided by a light source than can target discrete portions of the dispensed composite filament. For this purpose, the UV radiation source can be a light source integrated with the nozzle or a steered light source. As the composite filament is dispensed, UV radiation is directed onto the composite filament.

Abstract: A nozzle for dispense of a material that is a composite of fillers such as short fibers (e.g. carbon fibers) and a polymer matrix. The nozzle through which the composite material is dispensed has an expansion region through which the composite material flows. The expansion region dispenses a composite material wherein the fibers are substantially not aligned (e.g. in a random orientation with respect to each other in the polymer matrix).

Abstract: Aspects of the present disclosure are directed to a three-dimensional joint and/or formation thereof, such as by 3D-printing the joint. The joint is provided with an interface region having a curable material in a curable state. The joint is positioned with the interface region in contact with a joinable member, and the interface region is cured to form a bond between the joint and the joinable member. Such an approach may, for example, involve forming a mechanical and/or chemical bond with the joint. Further, by utilizing such a joint (e.g., in a 3D-printed form), complex structural components can be formed from a curable material that can be partially cured with structures formed therein, and cured further to create the bond.