Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first module configured to discharge a material, a second module configured to compact the material, and an actuator connected to the second module and configured to apply a force to the second module. The system may further include a controller in communication with the actuator. The controller may be configured to determine an operating parameter of the print head, and to selectively adjust the force applied by the actuator to the second module based on the operating parameter.

Abstract: A system is disclosed for use in additively manufacturing an object. The system may have a support and a first module operatively mounted to an end of the support and configured to discharge a material during motion of the support to form an object. The system may also have a second module configured to sever the material, at least a third module configured to at least one of compact or cure the material, and an actuator configured to cause movement of the second and the at least a third modules relative to the first module.

Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a housing, a supply module operatively mounted to the housing and configured to hold a supply of continuous reinforcement, an impregnation module operatively mounted to the housing and configured to wet the continuous reinforcement with a matrix, and a clamping module operatively mounted to the housing downstream of the supply module relative to movement of a reinforcement through the print head. The clamping module may be configured to selectively clamp the continuous reinforcement. The additive manufacturing system may also include a controller in communication with the support and the print head and configured to coordinate operations of the support and the print head to fabricate a three-dimensional structure.

Abstract: A system is disclosed for additively manufacturing a structure. The system may have a support, and a print head operatively connected to and moveable by the support. The print head may include a first module configured to discharge a material, a second module configured to compact the material as it discharges from the first module, and a controller in communication with the second module. The controller may be configured to determine an as-discharged characteristic of the material, and to selectively adjust a force of the second module based on the as-discharged characteristic.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a continuous reinforcement, a second supply configured to hold a matrix separate from the continuous reinforcement, and a wetting mechanism in separate communication with the first and second supplies and configured to discharge the continuous reinforcement wetted with the matrix. The system may also include a controller programmed to selectively pressurize the second supply to direct the matrix to the wetting mechanism.

Abstract: A system is disclosed for use in additively manufacturing an object. The system may have a reinforcement supply, a matrix supply, and a wetting module configured to separately receive reinforcement from the reinforcement supply and matrix from the matrix supply and to discharge the reinforcement wetted with the matrix. The wetting module may include a body forming an enclosure and having an inlet end configured to receive the reinforcement and an outlet end configured to discharge the reinforcement wetted with the matrix. The wetting module may also include a plurality of nozzles dividing the enclosure into at least a wetting chamber.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.

Abstract: A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths within a first layer of the structure that passes through the joint in a first configuration. The method may further include applying a transformation to the first configuration to form a second configuration. The method may additionally include depositing a second plurality of paths within a second layer of the structure to at least partially overlap the first plurality of paths and pass through the joint in the second configuration.

Abstract: A method is disclosed for additively manufacturing of a joint within a structure using a composite material. The method may include depositing a first path of the composite material within a first layer at the joint. The first path may have a center portion at a center of the joint, and a first portion integral with the center portion and extending away from the center portion. The first portion may form at least part of a first branch having a first density. The center of the joint may have a second density. The first density may be greater than the second density.

Abstract: A method is disclosed for manufacturing a joint. The method may include depositing a first path of composite material within a first layer at the joint. The first path may have a center at a center of the joint, a first portion integral with the center portion and extending away from the center portion, and a second portion integral with the center and extending away from the center portion. The method may further include depositing a second path of composite material within the first layer at the joint. The second path may have a center at the center of the joint, and a first portion integral with the center of the second path and extending away from the center of the second path. The center portion of the second path may be parallel with, abut and be bonded to the center portion of the first path.

Abstract: A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths to form a base layer of a joint in the structure. The method may also include depositing a second plurality of paths that pass through the joint. At least one of the second plurality of paths may extend away from the base layer through free space.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.

Abstract: A method is disclosed for manufacturing a joint. The method may include depositing a first plurality of paths within a first layer. Each of the first plurality of paths may have a center portion, a first portion extending away from the center portion to at least partially form a first branch, and a second portion integral extending away from the center portion opposite the first portion to at least partially form a second branch. The method may further include depositing a second plurality of paths primarily within the first layer. Each of the second plurality of paths may have a center portion, and a first portion extending away from the center portion to at least partially form a third branch of the joint. The second plurality of paths may cross over and be bonded to the first plurality of paths to form spaced-apart bumps that extend into a second layer.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may have a first tool center point associated with discharge of a first material, and a second tool center point associated with discharge of a second material that is a type different than the first material.

Abstract: A method is disclosed for additively manufacturing a structure. The method may include discharging from a print head a first layer of material inward of an outer boundary of the structure. The method may also include discharging from the print head a second layer of material adjacent the first layer and cantilevering past an edge of the first layer. The method may further include compacting a portion of the second layer of material cantilevered past the edge of the first layer to extend into and form a portion of the first layer of material.

Abstract: A system is disclosed for additively manufacturing an object. The system may include a first module configured to discharge a composite material including a continuous reinforcement and a matrix, and a cutting module located downstream of the first module and configured to sever the continuous reinforcement discharging from the first module. The cutting module may include a cutting mechanism configured to engage the continuous reinforcement, and a guide moveable to selectively abut the reinforcement during engagement of the reinforcement by the cutting mechanism.

Abstract: A nozzle is disclosed for use in an additive manufacturing print head. The nozzle may include a body having a central passage with an entrant end and an exit end, and a shoulder protruding radially outward from the body at a location between the entrant and exit ends. A groove may be formed within an outer surface of the body at a location between the shoulder and the entrant end. The groove may be configured to receive a seal.

Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a supply module configured to hold a reinforcement, and a wetting module. The wetting module may include a body with an inlet configured to separately receive the reinforcement and a matrix, and an outlet configured to discharge the reinforcement wetted with the matrix. The print head may also include a teasing mechanism disposed between the inlet and the outlet. The teasing mechanism may have multiple operating positions configured to affect varying levels of pressure against the reinforcement.

Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material, a leading device, and a trailing device pivotally connected to the leading device. The leading device may be configured to engage and move over the material after discharge. The trailing device may be configured to engage and move over the material at a location trailing the leading device.