Gradient and Discrete Region Composites Produced by Solid Free Form Fabrication Techniques

Abstract

AbstractStereolithography patterns have been used to create composites with gradient properties. Patterns are produced with an open cellular or columnar structure inside a surface shell. This serves as a host for filler materials, generally epoxies or polyurethane matrices loaded with various fibers or microspheres. Regions within a single object may be separated by thin barriers, allowing filling with different matrix materials to create regions of differing local properties. The internal structure can also be continually gradated in dimension to produce composites with properties ranging from that of the filler material to that of the SFF material, currently epoxy or ABS plastic. This is a general set of processes that can be applied to a variety of existing Solid Freeform Fabrication systems.