Abstract: A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to make a determination associated with the structure being a performance-critical part and, based on the determination, selectively implement a first slicing technique or a second slicing technique to divide a virtual model of the structure into a plurality of planes. The processor may be further configured to execute the computer-executable instructions to cause the additive manufacturing machine to deposit composite material in layers corresponding to the plurality of planes.

Abstract: A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to determine if a tool path to be followed by the additive manufacturing machine during manufacture of the structure is located in free-space or on top of another tool path. When the tool path is located in free-space, the processor may be further configured to execute the computer-executable instructions to make a determination regarding a curvature of the tool path, and to selectively cause the additive manufacturing machine to fabricate a support for the tool path based on the determination.

Abstract: A head is disclosed for use with a continuous manufacturing system. The head may have a housing configured to receive a matrix and a continuous fiber, and a diverter located at an end of the housing. The diverter may be configured to divert radially outward a matrix-coated fiber. The head may also include a cutoff having an edge configured to press the matrix-coated fiber against the diverter.

Abstract: A head is disclosed for use with an additive manufacturing system. The head may include a nozzle configured to discharge multiple fiber strands oriented transversely adjacent each other relative to a travel direction of the head. The head may also include a matrix supply separately associated with each of the multiple fiber strands.

Abstract: A tension mechanism is disclosed for use with a print head of an additive manufacturing system. The tension mechanism may include a first guide roller configured to receive a continuous reinforcement making up a portion of a composite structure. The tension mechanism may also include a second guide roller spaced apart from the first guide roller and configured to receive the continuous reinforcement in a straight-line trajectory from the first guide roller. The tension mechanism may further include a dancer located between the first and second guide rollers and configured to bias the continuous reinforcement away from the straight-line trajectory. At least one of the first and second guide rollers may have a concave outer profile configured to axially spread out the continuous reinforcement.

Abstract: An additive manufacturing system may include a head configured to discharge a matrix-coated reinforcement, a support configured to move the head during discharging, and a cure enhancer configured to cure the matrix as the matrix-coated reinforcement discharges from the head. The additive manufacturing system may also include a controller in communication with the head, the support, and the cure enhancer. The controller may be configured to receive specifications for a structure to be fabricated, and to determine an anchor point from which the matrix-coated reinforcement will be pulled during fabrication of the structure. The controller may also be configured to regulate operation of the head, the support, and the cure enhancer to manufacture the structure and the anchor point.

Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a matrix reservoir, and a fiber guide configured to separately receive a plurality of matrix-wetted reinforcements from the matrix reservoir. The system may also include a die configured to receive the plurality of matrix-wetted reinforcements from the fiber guide and to cause the plurality of matrix-wetted reinforcements to converge into a ribbon. The system may additionally include a cure enhancer configured to cure the matrix in the composite material during discharge of the ribbon from the die, and a support configured to move the die in multiple dimensions during discharge of the ribbon.

Abstract: A system for additively manufacturing a composite structure is disclosed. The system may include a print head configured to discharge a matrix-coated reinforcement, and a support configured to move the print head in multiple dimensions during discharging of the matrix-coated reinforcement. The system may further include at least one cure enhancer located offboard the print head, and a controller in communication with the support and the at least one cure enhancer. The controller may be configured to selectively activate the at least one cure enhancer to expose the matrix-coated reinforcement to a cure energy during discharging of the matrix-coated reinforcement.

Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include discharging from a nozzle into a feature of an existing component a first track of material including at least a liquid matrix. The method may also include discharging from the nozzle into the first track of material a second track of material including at least one of a wire and an optical fiber, and curing the liquid matrix.

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: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head configured to wet a continuous reinforcement with a liquid matrix and discharge the wetted continuous reinforcement. The print head may be operatively connected to and moveable by the support during discharge. The additive manufacturing system may also include a matrix control mechanism configured to selectively adjust an amount of matrix on the continuous reinforcement being discharged from the print head.

Abstract: A print head is disclosed for use in an additive manufacturing system. The print head may include an outlet configured to discharge a material, and a compacting device mounted to trail behind the outlet during movement of the print head in a normal direction. The print head may also include a spring configured to bias the compacting device against the material and to allow movement of the compacting device in a direction parallel with a discharge direction of the material through the outlet, and a locker configured to selectively lock a position of the compacting device relative to the outlet.

Abstract: A head is disclosed for use with an additive manufacturing system. The head may include a housing, and a matrix reservoir disposed inside of the housing. The head may also include at least one roller located inside of the housing and configured to engage at least one of a ribbon and a sheet of reinforcement passing through the head. The head may further include a nozzle fluidly connected to the matrix reservoir, and a cure enhancer located outside of the housing and adjacent the nozzle.

Abstract: A vehicle body may have an internal skeleton forming a wing shape, and a skin formed over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. The plurality of continuous fibers may curve from a base end near a fore/aft center of the wing shape outward toward leading and trailing edges of the wing shape at a tip end.

Abstract: 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.

Abstract: A head is disclosed for use with an additive manufacturing system. The head may include a matrix reservoir, and a plurality of nozzles simultaneously fluidly connected to the matrix reservoir. The head may also include at least one hinge connecting the plurality of nozzles.

Abstract: A print head is disclosed for use with an additive manufacturing system. The print head may include a matrix reservoir, and a nozzle base connected to an end of the matrix reservoir. The nozzle base may have a plurality of attachment features formed within an exposed surface. The print head may further include a plurality of available dies separately connectable to the nozzle base via the plurality of attachment features. Attachment of the plurality of available dies to the nozzle base may establish fluid communication with the matrix reservoir.

Abstract: A matrix supply is disclosed for use with an additive manufacturing system. The matrix supply may include a matrix chamber configured to fluidly communicate a liquid matrix with a print head of the additive manufacturing system. The matrix supply may also include a supply conduit fluidly connected to the matrix chamber, a valve disposed within the supply conduit, and an inlet configured to pass a continuous reinforcement through the matrix chamber to the print head of the additive manufacturing system.

Abstract: A structure is disclosed that is additively manufactured. The structure may include at least one continuous reinforcement, and a healing matrix associated with the at least one continuous reinforcement. Wherein a cure energy is applied to the at least one continuous reinforcement at a time of failure, the healing matrix is caused to cure and shore up the at least one continuous reinforcement.

Abstract: A method and apparatus is disclosed for additive manufacturing and three-dimensional printing, and specifically for extruding tubular objects. A print head extrudes a curable material into a tubular object, while simultaneously curing the tubular object and utilizing the interior of the cured portion of the tubular object for stabilizing and propelling the print head.