Ford Motor Company
METHODS FOR MAKING 3D PARTS USING COMPOSITE BASED ADDITIVE MANUFACTURING WITH PERFORATED SHEETS AND PARTS FORMED THEREFROM

Abstract:

A method of forming a 3D part includes applying liquid on a pattern on at least some of a plurality of sheets, applying a bonding agent on the liquid pattern on the at least some of the plurality of sheets, and forming perforations within the plurality of sheets along a perforation outline. The plurality of sheets are bonded together at the patterns between sheets via the bonding agent and a 3D pre-form within a stack of the plurality of sheets is formed. The perforations within each sheet bounds the pattern on each sheet and excess sheet material is removed from the stack of sheets bonded together by separating the plurality sheets along the perforations. Removal of the excess sheet material provides a semi-finished 3D part. The semi-finished 3D part may be further processed, e.g., by bead blasting, to provide a finished 3D part.