Continuous fiber-reinforced component fabrication

Abstract

A machine for fabricating a fiber-reinforced component by additive manufacture is disclosed. The machine may have a surface, a matrix feed configured to deposit a plurality of matrix layers on the surface, and a fiber feed configured to deposit a fiber layer on at least one of the plurality of matrix layers. The deposition of the plurality of matrix layers and the fiber layer may be controlled by a computer.

What is claimed is: 
     
         1 . A machine for fabricating a fiber-reinforced component by additive manufacturing comprising:
 a surface;   a matrix feed configured to deposit a plurality of matrix layers on the surface; and   a fiber feed configured to deposit a fiber layer at least one of the plurality of matrix layers, the deposition of the plurality of matrix layers and the fiber layer being controlled by a computer.   
     
     
         2 . The machine, according to  claim 1 , wherein the fiber layer comprises a continuous fiber. 
     
     
         3 . The machine, according to  claim 1 , further comprising a first energy-source configured to soften any of the plurality of matrix layers. 
     
     
         4 . The machine, according to  claim 3 , further comprising a pressure source configured to press the fiber layer into a previously deposited matrix layer. 
     
     
         5 . The machine, according to  claim 4 , wherein the pressure source emits heated air under a pressure. 
     
     
         6 . The machine, according to  claim 4 , further comprising a second energy source configured to melt any of the plurality of the matrix layers. 
     
     
         7 . The machine, according to  claim 6 , wherein a truck supports the matrix feed and the fiber feed. 
     
     
         8 . The machine, according to  claim 7 , wherein the truck further supports the first energy source, the pressure source, and the second energy source. 
     
     
         9 . The machine, according to  claim 7 , wherein the computer is operatively associated with the truck to control movement of the truck with respect to the surface. 
     
     
         10 . The machine, according to  claim 7 , wherein the matrix layer comprises one or more polymers. 
     
     
         11 . A method for fabricating a fiber-reinforced component by additive manufacturing with a three-dimensional printing machine, comprising:
 depositing with the three-dimensional printing machine a matrix layer on a surface; and   depositing a fiber layer with the three-dimensional printing machine on a previously deposited matrix layer, the fiber layer comprising a continuous fiber.   
     
     
         12 . The method, according to  claim 11 , further comprising depositing a subsequent matrix layer on the fiber layer. 
     
     
         13 . The method, according to  claim 12 , further comprising embedding the fiber layer into the previously deposited matrix layer. 
     
     
         14 . The method, according to  claim 13 , further comprising fusing the previously deposited matrix layer and the subsequent matrix layer. 
     
     
         15 . The method, according to  claim 14 , wherein the method is automated and controlled by a computer. 
     
     
         16 . A fiber-reinforced component fabricated by an additive manufacturing process comprising:
 depositing a matrix layer on a surface; and   depositing a fiber layer on a previously deposited matrix layer, the fiber layer comprising a continuous fiber.   
     
     
         17 . The component, according to  claim 16 , further comprising depositing a subsequent matrix layer on the fiber layer. 
     
     
         18 . The component, according to  claim 17 , further comprising embedding the fiber layer into the previously deposited matrix layer. 
     
     
         19 . The component, according to  claim 18 , further comprising fusing the previously deposited matrix layer and the subsequent matrix layer. 
     
     
         20 . The component, according to  claim 19 , wherein the additive manufacturing process is automated and controlled by a computer.