A system (10) is disclosed for additively manufacturing a composite structure (12). The system may include a support (14), and a print head (16) operatively connected to and moveable by the support. The print head may include a supply of continuous reinforcement (19), an outlet (54) configured to discharge the continuous reinforcement, and a tensioning module (48) disposed between the supply and outlet. The tensioning module may be configured to generate a signal indicative of at least one of a tension in the continuous reinforcement and a position of a tensioning module. The system may also include a processor (20) programmed to selectively cause the supply to dispense the continuous reinforcement based on the signal.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
A method is disclosed for additively manufacturing a composite structure. The method includes receiving from a user a sketch of a cross-section of the composite structure and a desired height. The method includes automatically generating a virtual model of the composite structure having a plurality of layers (1202), each with a thickness related to the height. The method further includes receiving from the user at least one infill pattern (1204) for at least one of the plurality of layers, and causing an additive manufacturing machine to deposit a continuous fiber along segments of the at least one infill pattern.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system includes a support and a print head operatively connected to and moveable by the support. The print head includes a housing (22), a supply module (44) operatively mounted to the housing and configured to hold a supply of continuous reinforcement, an impregnation module (48) operatively mounted to the housing and configured to wet the continuous reinforcement with a matrix, and a clamping module (46) operatively mounted to the housing downstream of the supply module relative to movement of a reinforcement through the print head. The clamping module is be configured to selectively clamp the continuous reinforcement. A controller in communication with the support and the print head is configured to coordinate operations of the support and the print head to fabricate a three-dimensional structure.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
An additive manufacturing system (10) is disclosed for use in fabricating a structure (12). The additive manufacturing system may include a support (14), and a print head (16) configured to discharge a material (R+M) and being operatively connected to and moveable by the support in a normal travel direction (34) during material discharge. The print head may include a module (22) located at a trailing side of the discharging material relative to the normal travel direction and being configured to compact the material and expose the material to a cure energy at a tool center point (TCP).
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
An additive manufacturing system (10) is disclosed for use in fabricating a structure (12). The additive manufacturing system may include a support (14), and an outlet (22) configured to discharge a material. The outlet may be operatively connected to and moveable by the support in a normal travel direction during material discharge. The outlet may include a guide (30), and a compactor (32) operatively connected to the guide at a trailing location relative to the normal travel direction. The compactor may be moveable in an axial direction of the guide. The outlet may also include at least one cure enhancer (18) mounted to move with the compactor relative to the guide. The at least one cure enhancer may be configured to expose the material to a cure energy.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A print head for an additive manufacturing system, comprising: a first end configured to receive a continuous reinforcement; a second end configured to discharge the continuous reinforcement at least partially coated in a matrix; a cutting module disposed between the first and second ends, the cutting module including: a blade, and a first actuator operatively connected to the blade, the first actuator configured to actuate the blade towards the continuous reinforcement to cut the continuous reinforcement into a first section and a second section, the first section being located upstream of the blade and the second section being located downstream of the blade; a clamping module configured to clamp the first section of the continuous reinforcement during a cutting of the continuous reinforcement; a second actuator configured to actuate and push the first section of the continuous reinforcement past the blade and out of the second end of the print head after the cutting of the continuous reinforcement and a wetting module configured to at least partially coat the continuous reinforcement in the matrix, the continuous reinforcement being at least partially coated with the matrix upstream of the blade.
A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a compactor located at the discharging end and forming a tool center point for the print head.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
patents
