BACKGROUND

Fiber-reinforced polymer (FRP) composite objects have gained popularity in recent years, particularly in manufacturing large and small parts for aircraft (e.g., Boeing 747, Airbus A350, and Airbus A380) and electric automobiles (e.g., BMW i-Series). Conventional fabrication of FRP composite objects involves laying down fibers in the form of wovens, mats, tows, or rovings by hand or by machine to form a flat flexible preform. In order to produce a three-dimensional composite object, the flat flexible preform must be draped and manipulated into a three-dimensional mold, increasing production time and cost.

SUMMARY

In general, in one aspect, the invention relates to a method for generating a thermoset FRP composite preform. The method comprises: dispensing, from a print head of a 3D-printer, a dual-cure resin coated fiber comprising a dual-cure resin with an ultra-violet (UV)-curable component and a thermally-curable component; curing, during the dispensing of the dual-cure resin coated fiber, the UV-curable component with a UV light source such that the dual-cure resin coated fiber is partially cured and contacting lengths of the partially-cured dual-cure resin coated fiber bond together; and positioning the print head during the dispensing of the dual-cure resin coated fiber to three-dimensionally print the thermoset FRP composite preform.

In general, in another aspect, the invention relates to a system for generating a thermoset FRP composite preform. The system comprises: a 3D-printer that dispenses, from a print head, a dual-cure resin coated fiber comprising a dual-cure resin with a UV-curable component and a thermally-curable component; and a UV light source that cures, during the dispensing of the dual-cure resin coated fiber, the UV-curable component such that the dual-cure resin coated fiber is partially cured and contacting lengths of the partially-cured dual-cure resin coated fiber bond together, wherein the 3D-printer positions the print head during the dispensing of the dual-cure resin coated fiber to three-dimensionally print the thermoset FRP composite preform.

In general, in another aspect, the invention relates to a non-transitory computer readable medium (CRM) storing computer readable program code for generating a thermoset FRP composite preform. The computer readable program code causes a computer to control a 3D-printer to: dispense, from a print head of a 3D-printer, a dual-cure resin coated fiber comprising a dual-cure resin with a UV-curable component and a thermally-curable component; cure, during the dispensing of the dual-cure resin coated fiber, the UV-curable component with a UV light source such that the dual-cure resin coated fiber is partially cured and contacting lengths of the partially-cured dual-cure resin coated fiber bond together; and position the print head during the dispensing of the dual-cure resin coated fiber to three-dimensionally print the thermoset FRP composite preform.

Other aspects of the invention will be apparent from the following description and the appended claims.

