Markforged, Inc.

Benjamin Tsu Sklaroff

Gregory Thomas Mark

Abraham Lawrence Parangi

David Steven Benhaim

Rick Bryan Woodruff

A three-dimensional geometry is received, and sliced into layers. A first anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material is generated defining at least part of an interior of a first layer. A second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material defines at least part of an interior of a second layer. A generated isotropic fill material tool path defines at least part of a perimeter and at least part of an interior of a third layer intervening between the first and second layers.

Methods for fiber reinforced additive manufacturing

In a method for additive manufacturing, a multi-strand core reinforced filament including a flowable matrix material and substantially continuous reinforcing strands extending in a direction parallel to a length of the filament is supplied. A first consolidated composite swath of a height less than &#xbd; the width of the filament is deposited in a first reinforcement formation including at least one straight path and at least one curved path against a deposition surface, and a second consolidated composite swath of a height less than &#xbd; the width of the filament is deposited in a second reinforcement formation against the first consolidated composite swath. Each deposition flows the matrix material and applies an ironing force to spread the reinforcing strands within the filament against the underlying surface and/or previously deposited swath.

Composite filament 3D printing using complementary reinforcement formations

A method comprising receiving a first 3D toolpath defining a fill material curved shell, receiving first 2D toolpaths defining support material flat shells, receiving a second 3D toolpath defining a long fiber composite material curved shell, the long fiber composite material including a filament having a matrix embedding fibers having a length longer than two times a diameter of the filament, actuating a fill material deposition head to trace the first 3D toolpath to deposit the fill material curved shell non-parallel to a printing substrate, actuating a support material deposition head to trace the first 2D toolpaths to deposit support material in a succession of substantially flat shells, and actuating a long fiber deposition head to trace the second 3D toolpath non-parallel to the printing substrate to deposit the long fiber composite material curved shell to enclose at least a portion of the fill material curved shell.

Multilayer fiber reinforcement design for 3D printing

According to at least one aspect, embodiments of the invention provide a 3D printer comprising an anisotropic head that solidifies, along anisotropic toolpaths, fiber swaths having an anisotropic characteristic oriented relative to a trajectory of the anisotropic tool paths, an isotropic head that solidifies, along isotropic toolpaths, a substantially isotropic material, a motorized drive for moving the anisotropic head and a build plate supporting a printed part in at least three degrees of freedom, and a controller configured to control the 3D printer to build the printed part by solidifying the isotropic material along the isotropic tool paths, solidifying the anisotropic material in fiber swaths tracking a non-concentric set of anisotropic tool paths for at least a first sequence of parallel shells, solidifying the anisotropic material in fiber swaths tracking an outer concentric set of anisotropic tool paths for at least a second sequence of parallel shells.

In a 3D composite printer, toolpaths defining fill material shells are received, as are toolpaths defining support material shells. A 3D toolpath defining a long fiber composite material curved shell is also received. A fill material deposition head traces the toolpaths to deposit some of the fill material shells or support material shells at least in part non-parallel to a printing substrate. A long fiber deposition head traces the 3D toolpath at least in part non-parallel to the printing substrate to deposit the long fiber composite material curved, concave, ring, tube, or winding shells to enclose, surround, or envelop at least a portion of the fill or support material shells.

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Somerville, MA, United States of America

Benjamin Tsu Sklaroff