Abstract: In part, the disclosure relates to an applicator management system for fabricating 3D parts. The system includes a first applicator; a housing; a mount, wherein the mount is moveable in one or more directions within the housing; a build plate disposed within the housing, wherein position of build plate is adjustable in one or more directions; and an applicator changer coupled to the moveable mount; wherein the applicator changer includes a first interface to operatively engage the first applicator and a second applicator. In part, the disclosure relates to the use of magnetic coupling or docking system.

Abstract: In one aspect, the disclosure relates to a method of fabricating a three-dimensional object. The method includes transporting a first material, in a first state, the first material comprising a thermoplastic matrix and M reinforcing fibers, wherein the first material has a first cross-sectional profile; depositing, heating, and consolidating a segment of the first material such that it is placed in a second state having a second cross-sectional profile; and repeating the foregoing steps until a unitary composite object has been formed by M segments of the first material. In one embodiment, consolidation is performed to achieve a porosity of less than about 2%. In one embodiment, a ratio of volume of the reinforcing fibers to matrix first material ranges from about 0.5 to about 0.7.

Abstract: A method and system for manufacturing a part where a three-dimensional support is printed, using a fused filament fabrication-based print head (XX), wherein the support comprises layers of fused polymer filament; and heating one or more segments of prepreg thermoplastic tape (105), using a heating element disposed in a tape deposition head (100); depositing one or more heated segments of prepreg thermoplastic tape on the three-dimensional support in one or more directions; compacting with a roller (125), the one or more segments of prepreg thermoplastic tape such that the one or more segments conform to the support; and repeating depositing and compacting steps and periodically changing the one or more directions until a fiber-reinforced multi-layer part comprising one or more surfaces is formed, wherein at least one surface of the one or more surfaces is defined by the support.