US 10,889,044 B2
Method of printing parts in a layerwise manner with one or more internal woven panels under tension
J. Samuel Batchelder, Somers, NY (US); and S. Scott Crump, Wayzata, MN (US)
Assigned to Stratasys, Inc., Eden Prairie, MN (US)
Filed by Stratasys, Inc., Eden Prairie, MN (US)
Filed on Jan. 11, 2019, as Appl. No. 16/245,710.
Prior Publication US 2020/0223121 A1, Jul. 16, 2020
Int. Cl. B29C 48/30 (2019.01); B29C 48/05 (2019.01); B29C 64/209 (2017.01); B29C 48/92 (2019.01); B29C 64/106 (2017.01); B33Y 70/00 (2020.01); B33Y 40/00 (2020.01); B33Y 30/00 (2015.01)
CPC B29C 48/3001 (2019.02) [B29C 48/05 (2019.02); B29C 64/209 (2017.08); B29C 48/92 (2019.02); B29C 64/106 (2017.08); B33Y 30/00 (2014.12); B33Y 40/00 (2014.12); B33Y 70/00 (2014.12)] 23 Claims
OG exemplary drawing
 
1. A method of producing a part printed in a layer-wise manner the method comprising the steps of:
providing a pre-fabricated starter piece with a first course of loops;
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;
knitting a next course of loops to the existing course of loops to form a portion of an internal woven reinforcement network;
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;
repeating the knitting and printing steps to create an internal woven reinforcement network within the printed part until the part is completed;
engaging the starter piece from a first end of the completed part;
engaging a course of loops extending from a second end of the completed part with a tensioning device;
heating the part to a temperature where the material is flowable;
tensioning the reinforcement network by applying a force to pull the starter piece and the tensioning device in opposite directions from each other to place the internal woven reinforcement network into tension; and
cooling the part to a temperature where the thermoplastic material solidifies such that the internal woven structure remains in tension.