Ford Global Technolgoies, LLC

Other

Ellen Cheng-chi Lee

Deborah Frances Mielewski

Matthew Cassoli

Mark Edward Nichols

Christopher Michael Seubert

Robert D Bedard

Amy Ellen Langhorst

Esin Gulari

Xiaojiang Wang

Shannon Christine Bollin

Charles W Manke

Angela Harris

Kevin Richard John Ellwood

Alper Kiziltas

Scott A Wojan

Junko Pauken

Haoliang Michael Sun

Emily Ann Ryan

Giuseppe Domenic Lacaria

Matthew Linden Bedell

Sushmit Chowdhury

Nicholas Ryan Gunther

A method of forming a part includes 3D printing a photopolymerizable resin and forming a preformed part and subsequently post-curing the preformed part with electron beams. The preformed part may be cured via UV curing. A section of the preformed part post-cured with electron beams may have a thickness of at least 1.0 centimeter, for example, at least 2.0 centimeters or at least 3.0 centimeters. An electron beam dosage to post-cure the preformed part may be between 10 kilogray (kGy) and 100 kGy. The preformed part may be 3D printed using stereolithography (SLA), digital light processing (DLP) or material jetting (MJ) and the photopolymerizable resin may include at least one of an acrylate functional polymer and a methacrylate functional polymer. In the alternative, or in addition to, the photopolymerizable resin may include at least one of a urethane, a polyester, and a polyether.

Methods of post-curing additive manufacturing parts using electron beams

A method of forming an etched part includes forming a substrate including a thermoset resin and etching a surface of the substrate. The thermoset resin includes a vat photopolymerization (VPP) thermoset resin and at least one of an etchable phase and etchable particles disposed within the VPP thermoset resin. The etching removes the etchable phase from the VPP thermoset resin at the surface of the substrate such that a plurality of micro-mechanical bonding sites are formed on an etched surface of the substrate.

Method of forming an etched part and a method of forming a metal plated part

A method of additive manufacturing a part via vat photopolymerization (VPP) includes irradiating a first material through a first transparent wall of a first material tank and forming a first section of an nth layer of the part on a platform, positioning the platform with the first section of the nth layer in a second material tank with a distance between the first section of the nth layer and a second transparent wall, and irradiating a second material such that a second section of the nth layer of the part is formed on the platform adjacent to the first section of the nth layer. The method repeats forming first and second sections of additional layer until a predetermined number of total layers are formed. Positioning the first and second sections with a distance between the second and first transparent walls, respectively, inhibits crashing during forming of the part.

Offset layer slicing and offset layer forming of vat photopolymerization additive manufactured parts

A thermoset resin for forming parts to be metal plated includes a vat photopolymerization (VPP) thermoset resin and an etchable phase disposed in the VPP thermoset resin. The etchable phase is etched from a surface of a part formed from the VPP thermoset resin such that a plurality of micro-mechanical locking sites is formed on the surface of the part. The etchable phase is at least one of organic particles, organic resins, inorganic particles, and copolymers of the VPP thermoset resin. For example, the etchable phase can be a polybutadiene phase and/or a mineral such as calcium carbonate.

Additively manufactured thermoset polymers for metal plating and metal plated parts formed therefrom

An additive article stabilizing method includes prior to polymerization, adding a radiation-activated stabilizing composition to a liquid resin, forming the article from the liquid resin, layer by layer, using radiation such that the stabilizing composition does not stabilize the liquid resin but the formed article, and neutralizing free radicals generated during a degradation process initiated by exposure of the article to additional radiation post-cure.

Stabilized additive manufacturing articles

An additive manufacturing method. The method includes mixing a reflective material including fibers with a photopolymer resin to form a resin mixture having a loading of the reflective material of at least 3 wt. %. The method further includes curing the resin mixture using a light source to form first and second individually cured layers and a bridge of a portion of the fibers between the two layers.

Additive manufacturing process

Articles, methods of making an article, and resin compositions are disclosed. An article is disclosed that includes a cured light-curable resin having dispersed therein a reflective material that reflects at least 85% of the visible light spectrum. A loading of reflective material may be at least 3 wt. % of the article and the reflective material may comprise over 50 vol. % of a total filler composition of the article. The reflective material may be a white or near-white material, such as cellulose fibers, talc powder, or soy flour. A method is disclosed that includes mixing a reflective material that reflects at least 85% of the visible light spectrum with a photopolymer resin at a loading of at least 3 wt. % to form a resin mixture and curing the resin mixture using a light source in an additive manufacturing process. The disclosed resins may reduce the curing time of additive manufacturing processes.

Accelerated cure time of polymer resins

A bio-based polyol-containing polymer foam material, which includes a bio-based polyol-containing polymer foam present in a bulk concentration of the bio-based polymer foam material of 99% by weight or greater; and a graphite material present in a bulk concentration of the bio-based polyol-containing polymer foam material of 1% by weight or less. The bio-based polyol-containing polymer foam material is especially suitable for automotive components having deadening and vibration management features.

Bio-based polyurethane foam materials including graphite materials

A method of forming a natural fiber polymer composite includes the steps of introducing into an extruder a polymer, a natural fiber and a supercritical fluid to form a natural fiber polymer mixture; and extruding the natural fiber polymer mixture to form the natural fiber polymer composite at a temperature below a standard melting temperature of the polymer alone. The supercritical fluid may be introduced after the polymer is introduced into the extruder. The supercritical fluid may be introduced before or after the natural fiber is introduced into the extruder.

Method of forming natural fiber polymer composite

An injection molding apparatus and method are provided. The method includes a molded cavity coupled to a resin injection apparatus which injects molten resin under pressure with a gas such that the resin foams within the mold cavity. An electrical heater is in contact with a first cavity surface, and a cooling medium cools the mold. The resin may include metallic flakes.

Foamed resin injection molding method

A compostable interior panel for use in a vehicle includes an injection molded compostable polymer. A layer is disposed about the compostable polymer and comprises a composting-resistant polymer having a thickness ranging from 10 &#x3bc;m to 175 &#x3bc;m. The compostable polymer and the composting-resistant polymer are substantially insoluble in one another when liquid.

Compostable interior panel for use in a vehicle and method of manufacture

The present invention discloses a method for dispersing and exfoliating fillers in a thermoplastic polymer by sonicating a mixture of the thermoplastic polymer and the filler. The method of the present invention is particularly useful in dispersing layered silicate clays in thermoplastic polymers. A reinforced composite comprising a filler dispersed in a thermoplastic polymer is also disclosed. In another variation, the method of the invention is incorporated into conventional plastic extruder and injection molding equipment.

Method for producing a well-exfoliated and dispersed polymer silicate nanocomposite by ultrasonication

A washer system which includes a first reservoir containing a freezable washer liquid and having a drain port therein. The drain port is in fluid communication with the freezable washer liquid when the first reservoir is in at least a full state. The washer system also includes a temperature sensor for measuring a critical temperature corresponding to approximately a freezing temperature of the freezable washer liquid, a drain plug sealingly communicating with the drain port, and an electrical control unit in operative communication with the temperature sensor and the drain plug. The electrical control unit controls the drain plug to drain the liquid from the first reservoir in response to the critical temperature.

Automotive washer system utilizing a freezable washer liquid and a freeze-resistant washer liquid

The present invention involves a method of preparing a reinforced polymer providing improved mechanical properties. The method includes providing particles of the layered silicate and a supercritical fluid. The method further includes mixing the layered silicate with a polymer to form a treatable silicate-polymer mixture and contacting the treatable mixture with the supercritical fluid to exfoliate the silicate particles so that the particles disperse within the polymer. The method further includes depressurizing the contacted mixture to exfoliate the layered silicate so that the layers are substantially dispersed within the polymer to define a reinforced polymer.

System and method of preparing a reinforced polymer by supercritical fluid treatment

The present invention involves a system and method of delaminating a layered silicate to provide improved mechanical properties to select materials such as polymers. The method includes providing particles of the layered silicate and a supercritical fluid. The method further includes contacting the layered silicate particles with the supercritical fluid to define contacted layered silicate particles and catastrophically depressurizing the contacted layered silicate particles to exfoliate the layered particles so that the layered particles are substantially dispersed, defining treated silicate particles.

Growing community of inventors

Ann Arbor, MI, United States of America

Ellen Cheng-chi Lee