Idaho Patent of the Month – August 2024

Continuous Composites, Inc., an additive manufacturing firm committed to innovation, has introduced a revolutionary print head for additive manufacturing that significantly enhances the capabilities of continuous fiber 3D printing (CF3D®). 

This newly patented print head design integrates a sophisticated wetting module with a remote matrix supply, which allows for precise control over the reinforcement material as it is combined with a liquid matrix to form high-strength, lightweight structures. By utilizing a cartridge system that pushes the matrix towards the wetting module, the print head ensures consistent and accurate fiber wetting, which is crucial for maintaining the structural integrity of the printed object.

One of the standout features of this invention is its ability to manage the liquid matrix supply with remarkable precision. The inclusion of sensors that monitor the position of the matrix within the cartridge allows for real-time adjustments, ensuring optimal wetting and curing of the fibers. This results in a more reliable and efficient manufacturing process, capable of producing complex, unsupported structures in free space.

The design also addresses common issues in continuous fiber 3D printing, such as fiber cutting and automated restarting, which can often disrupt production. Continuous Composites’ print head streamlines these processes, minimizing downtime and enhancing the overall accuracy of the final product. This advancement not only improves the strength and durability of printed components but also opens up new possibilities for complex geometries in aerospace, automotive, and other high-performance industries.

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