Apparatus and Process for Forming Three-Dimensional Objects

Abstract

An apparatus for forming a three-dimensional (3D) object includes a 3D printing head, for fabricating a first portion of the 3D object by forming a plurality of successive layers of a first material. The apparatus also includes a delivery head for fabricating a second portion of the 3D object by dispensing onto the first portion of the 3D object a plurality of layers of a continuous-fiber reinforced second material. Further, the delivery head includes comprising a roller for pressing the continuous-fiber reinforced second material into place during the dispensing thereof. A controller controls the 3D printing head and the delivery head to cooperatively form the 3D object, based on a dataset corresponding to a 3D object model.

1 . An apparatus for forming a three-dimensional (3D) object, comprising:
 a head assembly comprising:
 a 3D printing head for fabricating a first portion of the 3D object by forming a plurality of successive layers of a first material; 
 a delivery head for fabricating a second portion of the 3D object by dispensing onto the first portion of the 3D object a plurality of layers of a continuous-fiber reinforced second material, and comprising a roller for pressing the continuous-fiber reinforced second material into place during the dispensing thereof; 
   a gantry robot or an articulated arm robot with five or more axes of movement and configured to move the head assembly in all of the five or more axes of movement simultaneously; and   a controller for receiving a dataset corresponding to a 3D object model and for controlling the gantry robot or the articulated arm robot, the 3D printing head and the delivery head to form the 3D object based on the dataset.   
     
     
         2 . The apparatus according to  claim 1 , wherein the delivery head comprises a heat source that is disposed adjacent to the roller, for heating the continuous-fiber reinforced second material immediately prior to said continuous-fiber reinforced second material being pressed into place. 
     
     
         3 . The apparatus according to  claim 1 , wherein the 3D printing head is a fused deposition modeling (FDM) head and wherein the first material is a thermoplastic resin. 
     
     
         4 . The apparatus according to  claim 1 , wherein the delivery head is one of an automated tape layup (ATL) head and an automated fiber placement (AFP) head. 
     
     
         5 . The apparatus according to  claim 1 , wherein the 3D printing head is fixedly mounted to the gantry robot and wherein the delivery head is mounted to the gantry robot via a linear actuator, the linear actuator for controllably extending and retracting the delivery head relative to the 3D object for selectively switching between operating the 3D printing head and operating the delivery head. 
     
     
         6 .- 10 . (canceled) 
     
     
         11 . A process for forming a three-dimensional object, comprising:
 receiving a dataset corresponding to a 3D object model;   using a controller, controlling a gantry robot or an articulated arm robot to move a head assembly carried thereby in all of five or more axes of movement supported by the gantry robot or the articulated arm robot, simultaneously, to form the 3D object by:
 fabricating a first portion of the 3D object based on the dataset by forming a plurality of successive layers of a first material using a 3D printing head; and 
 fabricating a second portion of the 3D object based on the dataset by dispensing onto the first portion of the 3D object a plurality of layers of a continuous-fiber reinforced second material using a delivery head and pressing the continuous-fiber reinforced second material into place during the dispensing thereof. 
   
     
     
         12 . The process according to  claim 11 , comprising switching between the 3D printing head and the delivery head a plurality of times while forming the 3D object. 
     
     
         13 . The process according to  claim 11 , wherein the 3D printing head is a fused deposition model (FDM) head and wherein the first material is a thermoplastic unreinforced resin. 
     
     
         14 . The process according to  claim 11 , wherein the delivery head is one of an automated tape layup (ATL) head and an automated fiber placement (AFP) head, and wherein the continuous-fiber reinforced second material comprises unidirectional fibers pre-impregnated with a matrix material. 
     
     
         15 . The process according to  claim 14 , wherein the unidirectional fibers are selected from the group consisting of glass, carbon, aramid and mineral fibers, and wherein the matrix material is compatible with the first material. 
     
     
         16 . The process according to  claim 14 , wherein the unidirectional fibers in adjacent layers of the plurality of layers of the continuous-fiber reinforced second material are arranged at one of 45°, 90° and 135°, plus or minus 15°, to one another. 
     
     
         17 . The process according to  claim 11 , wherein forming the plurality of successive layers of the first material using the 3D printing head comprises forming a stack of layers, each layer in the stack having a different shape in an X-Y plane. 
     
     
         18 .- 19 . (canceled) 
     
     
         20 . The process according to  claim 11 , further comprising the steps of:
 prior to receiving the dataset, providing a sheet-metal blank; and   coating at least a portion of at least one side of the sheet metal blank with a primer material,   
       wherein the plurality of successive layers of the first material are formed on the coated at least a portion of the sheet-metal blank. 
     
     
         21 - 41 . (canceled) 
     
     
         42 . The process according to  claim 11 , wherein the dataset further corresponds to a removable support member for the 3D object model, and further comprising:
 prior to fabricating the 3D object, fabricating the removable support member based on the dataset by forming a plurality of successive layers of a third material, wherein the 3D object is fabricated subsequently by dispensing the first material onto the removable support member to form the plurality of successive layers of the first material; and   removing the removable support member from the 3D object.   
     
     
         43 . The process according to  claim 11 , further comprising:
 receiving a second dataset corresponding to a removable support member for the 3D object model;   prior to fabricating the 3D object, fabricating the removable support member based on the second dataset by forming a plurality of successive layers of a third material, wherein the 3D object is fabricated subsequently by dispensing the first material onto the removable support member to form the plurality of successive layers of the first material; and   removing the removable support member from the 3D object.