Lawrence Livermore National Security, LLC (20240278499). ADDITIVE MANUFACTURING METHOD TO PRODUCE CARBON-CARBON PARTS WITH IMPROVED PROPERTIES AND REDUCED MANUFACTURING TIMES simplified abstract

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ADDITIVE MANUFACTURING METHOD TO PRODUCE CARBON-CARBON PARTS WITH IMPROVED PROPERTIES AND REDUCED MANUFACTURING TIMES

Organization Name

Lawrence Livermore National Security, LLC

Inventor(s)

James Lewicki of Oakland CA (US)

ADDITIVE MANUFACTURING METHOD TO PRODUCE CARBON-CARBON PARTS WITH IMPROVED PROPERTIES AND REDUCED MANUFACTURING TIMES - A simplified explanation of the abstract

This abstract first appeared for US patent application 20240278499 titled 'ADDITIVE MANUFACTURING METHOD TO PRODUCE CARBON-CARBON PARTS WITH IMPROVED PROPERTIES AND REDUCED MANUFACTURING TIMES

The patent application describes systems for manufacturing a stage 1 carbon-carbon (CC) part using resin infused with fibers and UV initiators, with an additive manufacturing system determining tool paths for engineered characteristics.

  • Resin infused with chopped fibers, milled fibers, or continuous fibers is used in manufacturing the stage 1 CC part.
  • The resin includes UV initiators to enable UV gelation upon exposure to UV light.
  • An additive manufacturing system determines tool paths for providing engineered characteristics to the part.
  • A print nozzle component extrudes the resin onto a sacrificial support material layer in desired orientations, layer by layer.
  • UV light initiates gelation of the resin as it is extruded, forming a precursor part with enhanced performance characteristics.
  • A pyrolysis subsystem can be used to create the final stage 1 CC part by pyrolyzing the precursor part.

Potential Applications: - Aerospace industry for lightweight and high-performance parts. - Automotive industry for high-strength components. - Defense industry for durable and heat-resistant materials.

Problems Solved: - Enables the manufacturing of complex carbon-carbon parts with enhanced performance characteristics. - Provides a method for precise fiber orientation within each layer.

Benefits: - Lightweight yet strong parts. - Enhanced performance characteristics. - Cost-effective manufacturing process.

Commercial Applications: Title: Advanced Carbon-Carbon Manufacturing Technology for Aerospace and Defense Industries This technology can be used in the aerospace and defense industries to produce high-performance parts with complex geometries, offering lightweight yet durable solutions for various applications.

Questions about Carbon-Carbon Manufacturing: 1. How does the use of UV initiators impact the manufacturing process of carbon-carbon parts? UV initiators enable UV gelation of the resin, allowing for precise control over the curing process and enhancing the performance characteristics of the final part.

2. What are the key advantages of using additive manufacturing for producing stage 1 carbon-carbon parts? Additive manufacturing enables the creation of complex geometries and engineered characteristics in a cost-effective and efficient manner, making it ideal for producing high-performance components in industries like aerospace and defense.


Original Abstract Submitted

systems for manufacturing a stage 1 carbon-carbon (cc) part, including a resin infused with at least one of chopped fibers, milled fibers, or a continuous fiber. the resin further may include at least one uv initiator to render the resin uv gellable upon exposure to uv light. an additive manufacturing (am) system determines and provides tool paths needed to provide an engineered characteristic to the stage 1 cc part. a print nozzle component of the am system extrudes the resin in accordance with the tool paths onto a sacrificial support material layer, such that the fiber(s) are deposited in desired orientations, within each layer, in a layer-by-layer printing operation. a uv light illuminates the resin after extrusion to initiate gelation of the resin as the resin is extruded onto the sacrificial material layer, to thus form a precursor part having an imparted or enhanced performance characteristic. a pyrolysis subsystem may be used for pyrolyzing the precursor part to create the stage 1 cc part.

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