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: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and an outlet 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, and a compactor 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 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.

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 method is disclosed for additively manufacturing a composite structure. The method may include discharging a composite material to form a first layer having a first void, and discharging the composite material adjacent the first layer to form a second layer having a second void. The method may further include discharging a material into the first and second voids to lock the first and second layers together.

Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head, and a support configured to move the print head. The support may include a first link, a second link rotationally connected to the first link at a joint, and an encoder-less motor rigidly mounted to the first link and configured to drive rotation of the second link relative to the first link. The support may also include a sole encoder associated with the joint and configured to generate a signal indicative of an angular position of the first link relative to the second link. The additive manufacturing system may further include a controller in communication with the sole encoder and the encoder-less motor. The controller may be configured to selectively trim operation of the encoder-less motor based only on the signal.

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

Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include discharging a composite material from a print head and moving the print head during discharging to fabricate a preform from the composite material. The method may also include densifying the preform with a densifying material, and heating the preform to pyrolize the at least one of the composite material and the densifying 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 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, 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 additively manufacturing an object. The system may include a support, and a print head being connected to and moved by the support. The print head may have an outlet configured to discharge a material and a cutting mechanism configured to sever the material. The system may also include a controller in communication with the support and the print head. The controller may be configured to cause the print head to discharge material through an outlet, and cause the support to move the print head during discharging to form the object with the material. The controller may also be configured to cause the outlet of the print head to be moved a distance away from the object to provide a clearance between the outlet and the object, to cause a cutting mechanism to be moved through the clearance toward the material, and to cause the cutting mechanism to sever the material at a distance away from the outlet of the print head.

Abstract: A method is disclosed for fabricating an object. The method may include discharging a material through an outlet of a print head, and moving the print head during discharging to form the object with the material. The method may also include moving the outlet of the print head a distance away from the object to provide a clearance between the outlet and the object, moving a cutting mechanism through the clearance toward the material, and causing the cutting mechanism to sever the material at a distance away from the outlet of the print head.

Abstract: A head is disclosed for an additive manufacturing system. The head may include a first outlet configured to discharge a composite material to form an object. The head may also include a second outlet located upstream of the first outlet and configured to discharge fewer than all components of the composite material.

Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head having an outlet and being connected to and moveable by the support in a normal travel direction during discharge of material from the print head. The system may also include a first device operatively connected to the print head at a trailing location relative to the normal travel direction. The first device may be configured to expose the material to a cure energy. The system may further have a second device operatively connected to the print head at a location trailing the first device relative to the travel direction. The second trailing device configured to expose the material to a cure energy.

Abstract: A method is disclosed for additively manufacturing an object. The method may include discharging a composite material from a print head to form the object. The method may also include drawing out fewer than all components of the composite material from the print head prior to discharging.

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 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 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 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 supply of continuous reinforcement, an outlet configured to discharge the continuous reinforcement, and a tensioning module disposed between the supply and outlet. The tensioning module may be configured to generate a signal indicative of a tension in the continuous reinforcement. The system may also include a processor programmed to selectively cause the supply to dispense the continuous reinforcement based on the signal.

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.