Method of printing parts in a layerwise manner with one or more internal woven panels under tension

Abstract

A method of producing a part printed in a layer-wise manner includes providing a pre-fabricated starter piece with a first course of loops and printing a layer of a part by extruding one or more flowable thermoplastic materials about the existing course of loops such that an upper surface of the layer is at a selected height on the existing course of loops. The method includes knitting a next course of loops to the existing course of loops to form a portion of an internal woven reinforcement network, and printing a next layer of the part by extruding one or more flowable thermoplastic materials about the next course of loops such that an upper surface of the next layer is at a selected height on the next course of loops, wherein the next course of loops extends above the structure being printed and may function as an existing course of loops for subsequent knitting steps. The method includes repeating the knitting and printing steps to create an internal woven reinforcement network within the printed part until the part is completed. The starter piece and the course of loops extending from the second end of the completed part are engaged and heated to a temperature where the material is flowable. The reinforcement network is then placed into tension by applying a force to pull the starter piece and the course of loops in opposite directions from each other. The part is cooled to a temperature where the thermoplastic material solidifies such that the internal woven structure remains in tension.