Compound non-planar reinforced composite structures using layer-by-layer printing

Abstract

The composite 3D-printed curved elements and methods of making same provide arches and domes with high resistance to shear and flexural failure, thereby allowing the production of large, curved 3D-printed elements. The elements include a primary composite fused deposition modeling (FDM) 3D-printed component in the form of an arch or dome with one or more grooves on the outer surface, the inner surface, or both the outer and inner surfaces of the component. Each groove includes a plurality of deep, blind bores or slots spaced longitudinally along the bottom of the groove. In adjacent grooves, the slots are alternated in a zig-zag pattern, so that no two slots are too close to one another. Composite reinforcement materials are sequentially applied to the grooves and slots until they are filled.