Abstract: Additive manufacturing of continuous-fiber reinforced composites. More particularly, aspects of the invention relate to additive manufacturing systems and methods for fabricating 3D parts from continuous-fiber reinforced composites such as carbon-fiber or glass-fiber pre impregnated (“pre-preg”) sheets. A laser-assisted laminated object manufacturing method is used to fabricate continuous carbon fiber reinforced polymer composites (CFRPCs) using prepreg sheets with continuous-carbon fiber reinforcement. Graphene functions as a modifier between the prepreg sheets to improve the mechanical properties of the CFRPCs, specifically low porosity, high concentrations of continuous carbon fibers, and improved interfacial bonding strength. This composite architecture design, involving laminated continuous-carbon fiber reinforced prepreg sheets and graphene-modified interfaces, provides a readily scalable manufacturing method for producing 3D parts with desirable characteristics.

Abstract: Additive manufacturing systems and methods used for creating 3D parts from continuous-fiber reinforced composites such as, e.g., carbon-fiber or glass-fiber pre-impregnated tape are provided. The systems and methods lay tape in successive layers and cut each layer according to a 2D slice of a 3D CAD file. During the placement of each piece of tape, a laser welds the tape to other tape, eliminating the need for post-processing of each layer. By utilizing tape instead of large fiber-reinforced sheets, the systems and methods described herein reduce waste compared to known manufacturing techniques.

Abstract: Additive manufacturing systems and methods used for creating 3D parts from continuous-fiber reinforced composites such as, e.g., carbon-fiber or glass-fiber pre-impregnated tape are provided. The systems and methods lay tape in successive layers and cut each layer according to a 2D slice of a 3D CAD file. During the placement of each piece of tape, a laser welds the tape to other tape, eliminating the need for post-processing of each layer. By utilizing tape instead of large fiber-reinforced sheets, the systems and methods described herein reduce waste compared to known manufacturing techniques.