US 12,441,031 B2
System and method for designing and manufacturing objects having an optimised free-form with novel composite materials and the resulting object
Jorge Andrés Christie Remy-Maillet, Santiago (CL)
Assigned to Strong by Form SpA., Santiago (CL)
Appl. No. 17/642,159
Filed by Strong by Form SpA., Santiago (CL)
PCT Filed Sep. 13, 2019, PCT No. PCT/CL2019/000030
§ 371(c)(1), (2) Date Mar. 10, 2022,
PCT Pub. No. WO2021/046660, PCT Pub. Date Mar. 18, 2021.
Prior Publication US 2022/0314484 A1, Oct. 6, 2022
Int. Cl. B29C 70/30 (2006.01); B27D 1/08 (2006.01); B27G 11/00 (2006.01); B29C 33/38 (2006.01); B29C 43/00 (2006.01); B22F 10/10 (2021.01); B22F 10/85 (2021.01); B29C 43/02 (2006.01)
CPC B29C 33/3842 (2013.01) [B27D 1/083 (2013.01); B27G 11/00 (2013.01); B29C 43/003 (2013.01); B29C 70/30 (2013.01); B22F 10/10 (2021.01); B22F 10/85 (2021.01); B29C 43/02 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A method for manufacturing optimised free-form objects made of composite materials, that have been previously designed using computer programs for designing, simulating, analysing results, redesigning, simulating and analysing results N times in a data feedback loop, obtaining an optimised 3D design, comprising digital information, and converting the digital information of the design into manufacturing instructions for machinery that operates with computerised numerical control (CNC), wherein the composite material comprises fragments of material and binder(s);
wherein that it comprises the steps of:
(a) providing a mould of at least two parts, namely a lower part of the mould and an upper part of the mould, specific to the optimised design obtained through the design process for the design of the optimised free-form object;
(b) depositing on the lower part of the mould the binder(s) and the fragments of material in intentional and specific coordinates and orientations according to the manufacturing instructions calculated to optimise resistance to any stresses to be borne by the resulting optimised free-form object;
(c) pressing the fragments together with the binder between the parts of the mould;
(d) separating the parts of the mould to remove the finished optimised free-form object.