Abstract: A vehicle body may have an internal skeleton, and a skin fabricated in-situ over the internal skeleton. The internal skeleton may be fabricated via a first additive manufacturing system. The skin may be fabricated via a second additive manufacturing system that is different from the first additive manufacturing system.

Abstract: A method is disclosed for controlling an additive manufacturing system. The method may include causing a head to discharge composite material along a first trajectory, and activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory. The method may also include selectively deactivating the cure enhancer as the head nears a corner location, moving the head to a second trajectory after the head reaches the corner location, and reactivating the cure enhancer after moving the head to the second trajectory.

Abstract: A method of forming a composite structure with an additive manufacturing machine is disclosed. The method may include generating a vector field within a virtual model of the composite structure based on anticipated load conditions for the composite structure, and generating a plurality of NURBS curves inside the virtual model that have trajectories at least partially affected by the vector field. The method may further include selectively sequencing the plurality of NURBS curves to generate a tool path based on the analysis, and causing the additive manufacturing machine to discharge a path of composite material along the tool path.

Abstract: A head is disclosed for use with a manufacturing system. The head may have a housing configured to discharge a tubular structure reinforced with at least one continuous fiber and having a three-dimensional trajectory, and a cure enhancer operatively connected to the housing and configured to cure a liquid matrix in the tubular structure during discharge. The head may also have a nozzle configured to discharge a fill material into the tubular structure, and a wand extending from the housing to the nozzle.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to discharge a continuous reinforcement that is at least partially coated in a matrix, and a compactor configured to compact the continuous reinforcement and the matrix. The system may also include a cure enhancer configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, a discharge head connected to and moveable by the support, a supply of reinforcement, and a rotary tensioner located between the supply and the discharge head. The rotary tensioner may be configured to impart tension to the reinforcement and to generate a signal indicative of the tension. The system may further include a drive associated with the supply, and a controller in communication with the rotary tensioner and the drive. The controller may be configured to selectively adjust a feed parameter of the drive based on the signal to maintain a desired level of tension.

Abstract: A system is disclosed for additive manufacturing of a composite structure. The system may include an outlet through which a composite material is discharged, and a nose that is a component separate from the outlet and located at a distal end of the outlet. The nose may be biased axially relative to the outlet, from a retracted position to an extended position. The nose extends axially past the distal end of the outlet in the extended position.

Abstract: A method is disclosed for controlling an additive manufacturing system. The method may include causing a head to discharge composite material along a first trajectory, and activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory. The method may also include selectively deactivating the cure enhancer as the head nears a corner location, moving the head to a second trajectory after the head reaches the corner location, and reactivating the cure enhancer after moving the head to the second trajectory.

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 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 an outlet configured to discharge a continuous reinforcement at least partially coated in a matrix. The system may also include at least one doser located inside the print head and configured to at least partially coat the continuous reinforcement with the matrix, a sensor located downstream of the at least one doser and configured to generate a signal indicative of an amount of matrix coating the continuous reinforcement, and a controller in communication with the sensor and the at least one doser. The controller may be configured to direct a feedforward command to the at least one doser to cause the at least one doser to advance matrix toward the continuous reinforcement during passage of the continuous reinforcement through the print head, and to selectively adjust the feedforward command based on the signal.

Abstract: A method is disclosed for operating an additive manufacturing system. The method may include wetting a reinforcement with a thermoset matrix inside of a print head, discharging the wetted reinforcement from the print head, and moving the print head in multiple directions during discharging. The method may also include exposing the thermoset matrix wetting the reinforcement to a cure energy to initiate a chemical reaction, and directing a medium onto the wetted reinforcement to regulate a rate of the chemical reaction.

Abstract: A system is disclosed for additive manufacturing of a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may include an outlet configured to discharge a continuous reinforcement at least partially coated in a matrix. The outlet may be moveable relative to the support. The print head may also include at least one actuator configured to cause movement of the outlet relative to the support.

Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a composite material including a matrix and continuous reinforcement. The system may also include a shutter mechanism mounted to the head and configured to grasp the continuous reinforcement after discharge from the head.

Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head having a nozzle configured to discharge a composite material including a matrix and a reinforcement, and a cure enhancer configured to direct energy to the composite material to enhance curing of the matrix. The system may also include an optic adjustably positioned between the cure enhancer and the nozzle of the head.

Abstract: A head is disclosed for an additive manufacturing system. The head may include an outlet configured to discharge a continuous reinforcement at least partially coated in a liquid matrix. The head may also include a low-pressure port located upstream of the outlet and configured to draw out only liquid matrix.

Abstract: A head is disclosed for an additive manufacturing system having a support. The head may include a body connectable to and moveable by the support. The body may have a discharge end configured to discharge a composite material. The head may also include a wetting location inside the body at which a continuous reinforcement is wetted with a matrix to form the composite material, and a fiber-teasing mechanism located inside the body and upstream of the discharge end and the wetting location. The body and fiber-teasing mechanism may be configured to move together during movement of the support.

Abstract: A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a composite material including a matrix and a plurality of continuous reinforcements. The system may also include a cure enhancer configured to direct energy to the composite material to enhance curing of the matrix, and a shroud adjustably mounted to the head and configured to selectively block at least some of the energy from reaching the matrix.

Abstract: A method is disclosed for severing a continuous reinforcement from a print head at conclusion of an event during fabrication of a composite structure. The method may include moving the print head a distance away from the composite structure that provides clearance for a cutting mechanism between an outlet of the print head and the composite structure, and responsively causing the cutting mechanism to make a first cut of the continuous reinforcement at a boundary of the composite structure. The method may also include moving the print head to a waste discard location, and responsively causing the cutting mechanism to make a second cut of the continuous reinforcement at a desired distance offset from the outlet of the print head.

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 in multiple dimensions. The system may also include a cure enhancer mounted to the print head and configured to expose composite material discharging from the print head to energy, and a curing tool mounted to the print head downstream of the cure enhancer. The curing tool may be configured to expose the composite material to additional energy.