The Boeing Company
Composite feedstock strips for additive manufacturing and methods of forming thereof

Abstract:

Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A strip may include continuous fibers extending parallel to the principal axis of the strip. The cross-sectional distribution of these continuous fibers may be uneven. Specifically, the fibers may be concentrated near the center of the strip and may be positioned away from at least some portions of the strip surface. A strip may be formed by laminating a layup of one or more fiber-containing plies and one or more of resin plies. The position of the different types of plies in the layup is used to control distribution of the fibers and other materials within the strip. The laminated sheet is slit into multiple strips in a direction parallel to the continuous fibers. The cross-sectional profile of the slit strips may be later changed without disturbing orientation of the continuous fibers.