Aligned fiber reinforced molding

Abstract

Methods and apparatus for additive manufactures of complex parts using co-aligned continuous fibers are disclosed. Filament subunits having complex shapes are fabricated and inserted into a mold cavity. The layup is compression molded to form a complex part having high tensile strength.

1 . A method of fabricating a fiber-reinforced composite part, comprising:
 (a) placing a plurality of filament subunits into a mold cavity, wherein,
 each of the filament subunits independently comprises a plurality of fiber impregnated with a matrix material; 
 the plurality of fiber extends the length of the filament subunit; 
 each of the filament subunits is below a melt temperature of the matrix material; at least one of the filament subunits is non-linear; and 
 each of the filament subunits is not in the form of a tape or sheet of material; and 
   (b) consolidating the plurality of filament subunits in the mold cavity by compression molding to provide a fiber-reinforced composite part.   
     
     
         2 . The method of  claim 1 , wherein each of the filament subunits is independently selected from a linear filament subunit, a shaped filament subunit, or a combination thereof. 
     
     
         3 . The method of  claim 1 , wherein the plurality of filament subunits comprises a linear filament subunit. 
     
     
         4 . The method of  claim 1 , wherein the plurality of filament subunits comprises a shaped filament subunit. 
     
     
         5 . The method of  claim 1 , wherein each of the filament subunits comprises a shape that corresponds to the shape of a portion of the mold cavity in which the respective filament subunit is placed. 
     
     
         6 . The method of  claim 1 , wherein the matrix material comprises a thermoplastic composition. 
     
     
         7 . The method of  claim 1 , wherein the matrix material comprises a thermosetting composition. 
     
     
         8 . The method of  claim 1 , wherein the matrix material comprises a moldable ceramic composition. 
     
     
         9 . The method of  claim 1 , wherein the matrix material further comprises a filler. 
     
     
         10 . The method of  claim 9 , wherein the filler comprises an inorganic filler, an organic filler, or a combination thereof. 
     
     
         11 . The method of  claim 1 , wherein the plurality of fiber comprises silica fiber, glass fiber, carbon nanotubes, carbon fiber, polymer fiber, metal fiber, ceramic fiber, natural fiber, synthetic fiber, or a combination of any of the foregoing. 
     
     
         12 . The method of  claim 1 , wherein the plurality of fiber comprises braided fiber, woven fiber, twisted fiber, or a combination of any of the foregoing. 
     
     
         13 . The method of  claim 1 , wherein the plurality of fiber comprises co-aligned fiber. 
     
     
         14 . The method of  claim 1 , wherein the plurality of fiber comprises non-aligned fiber. 
     
     
         15 . The method of  claim 1 , wherein the plurality of fiber comprises a fiber bundle. 
     
     
         16 . The method of  claim 1 , wherein the plurality of fiber comprises more than one fiber bundle. 
     
     
         17 . The method of  claim 1 , wherein placing comprises placing a filament subunit onto an underlying filament, adjacent filament, or a combination thereof. 
     
     
         18 . The method of  claim 1  wherein placing comprises placing a filament subunit into the mold cavity. 
     
     
         19 . The method of  claim 1 , further comprising placing a filament subunit comprising non-aligned fiber into the mold cavity. 
     
     
         20 . The method of  claim 1 , further comprising placing pellets comprising the matrix material into the mold cavity. 
     
     
         21 .- 28 . (canceled)