Abstract: A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a compactor located at the discharging end and forming a tool center point for the print head.

Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement. The system may further include an external applicator configured to apply a matrix to the discharged continuous reinforcement, and a cure enhancer configured to expose the matrix to a cure energy at a side of the external applicator opposite the head.

Abstract: A printing apparatus is for printing a three-dimensional object having an operative surface; a plurality of supply hoppers for dispensing powder, the powder being adapted to be melted by an energy beam, wherein the supply hoppers are configured to form a plurality of vertically-aligned powder beds adjacent to one another on the operative surface simultaneously; and an energy source for emitting an energy beam onto each powder bed simultaneously to melt or fuse a topmost layer of the powder bed onto an underlying powder bed layer or substrate.

Abstract: A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a feeder located between the receiving end and the discharging end. The feeder may be configured to push the continuous reinforcement out of the print head at only select times during discharge of the continuous reinforcement and the matrix.

Abstract: An apparatus is for forming powder, and includes an energy source for emitting at least one energy beam onto a workpiece, the energy beam being configured to melt the workpiece, at least in part, to form at least one pool of molten material on the workpiece. The apparatus is configured to exert a force on the workpiece causing at least a bead of molten material to be ejected from the pool and solidify to form a particle of powder.

Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, and coating the continuous reinforcement with a first matrix component inside of the print head. The method may further include coating the continuous reinforcement with a second matrix component, discharging the continuous reinforcement through a nozzle of the print head, and moving the print head in multiple dimensions during the discharging. The first and second matrix components interact to cause hardening of a matrix around the continuous reinforcement.

Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, and coating the continuous reinforcement with a first matrix component inside of the print head. The method may further include coating the continuous reinforcement with a second matrix component, discharging the continuous reinforcement through a nozzle of the print head, and moving the print head in multiple dimensions during the discharging. The first and second matrix components interact to cause hardening of a matrix around the continuous reinforcement.

Abstract: A print head is disclosed for us with an additive manufacturing system. The print head may include a matrix reservoir configured to hold a supply of matrix, and a flop guide located within the matrix reservoir. The flop guide may be configured to at least partially surround a continuous reinforcement passing through the matrix reservoir. The print head may also include a nozzle connected to an end of the matrix reservoir downstream of the flop guide.

Abstract: A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement at least partially coated with a matrix. The head may have a matrix reservoir, and a nozzle connected to an end of the matrix reservoir. The system may further include a support configured to move the head during discharging, and a supply of matrix. The system may also include at least one sensor configured to generate a signal indicative of a matrix characteristic inside of the head, and a controller configured to selectively affect the supply of matrix based on the signal.

Abstract: A compactor is disclosed for use with an additive manufacturing print head. The compactor may include a housing connectable to the additive manufacturing print head. The compactor may also include a compacting wheel, and at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel. The compactor may further include a piston moveable to adjust a distance between the housing and the compacting wheel.

Abstract: A method is disclosed for additively manufacturing a composite wiring harness. The method may include directing a plurality of conductors through a print head, directing at least one reinforcement through the print head, and coating at least one of the plurality of conductors and the at least one reinforcement with a matrix material. The method may also include discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material from the print head, and exposing the matrix material during discharging to a cure energy to cause hardening of a sheath around the plurality of conductors.

Abstract: A method is disclosed for additively manufacturing a composite wiring harness. The method may include directing a plurality of conductors through a print head, directing at least one reinforcement through the print head, and coating at least one of the plurality of conductors and the at least one reinforcement with a matrix material. The method may also include discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material from the print head, and exposing the matrix material during discharging to a cure energy to cause hardening of a sheath around the plurality of conductors.

Abstract: A method is disclosed for additively manufacturing a composite wiring harness. The method may include directing a plurality of conductors through a print head, directing at least one reinforcement through the print head, and coating at least one of the plurality of conductors and the at least one reinforcement with a matrix material. The method may also include discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material from the print head, and exposing the matrix material during discharging to a cure energy to cause hardening of a sheath around the plurality of conductors.

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 cause the additive manufacturing machine to discharge a path of composite material, and to make a determination regarding existence of support located at a side of the path of composite material. The processor may be further configured to execute the computer-executable instructions to selectively cause the additive manufacturing machine to compact the path of composite material after discharge with a variable pressure that is based on the determination.

Abstract: A printing apparatus is for printing a three-dimensional object, comprising an operative surface, an energy source for emitting at least one energy beam onto the operative surface and at least one supply hopper for dispensing powder onto the operative surface, wherein the powder is adapted to be melted by the energy beam. The supply hopper is configured such that powder being dispensed by the supply hopper has an airborne density when travelling from the supply hopper to the operative surface, and wherein the density provides that the powder is not melted by the energy beam when the powder is travelling to the operative surface.

Abstract: A printing apparatus is for printing a three-dimensional object comprising an operative surface, at least one supply hopper for depositing layers of powder onto the operative surface and an energy source for emitting at least one energy beam onto the layers of powder. The supply hopper and energy source are configured such that when a topmost layer of powder is being deposited onto an underlying layer of powder on the operative surface, the direction travelled by the supply hopper when depositing the topmost layer is different to the direction travelled by the supply hopper when depositing the underlying layer, and at least one energy beam is emitted onto the topmost layer and at least one further energy beam is emitted onto the underlying layer, simultaneously, to melt, fuse or sinter the topmost and underlying layers.

Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, and coating the continuous reinforcement with a first matrix component inside of the print head. The method may further include coating the continuous reinforcement with a second matrix component, discharging the continuous reinforcement through a nozzle of the print head, and moving the print head in multiple dimensions during the discharging. The first and second matrix components interact to cause hardening of a matrix around the continuous reinforcement.

Abstract: A system is disclosed for additively manufacturing a structure. The system may include a feeder configured to feed a thin-film material through the system, and a cutter configured to cut out of the thin-film material a pattern associated with a shape of the structure at a particular layer within the structure. The system may also include a placer configured to place the pattern in at least one of a desired location and a desired orientation.

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 continuous reinforcement. The system may also include a cure enhancer configured to enhance curing of the matrix, and a support configured to move the head during discharging to create a structure having a three-dimensional trajectory. The system may further include a cutting mechanism operatively mounted to at least one of the head and the support, and configured to sever the continuous reinforcement after discharge from the nozzle. The cutting mechanism may include a blade, and an ultrasonic energy source connected to the blade.

Abstract: A continuous reinforcement is disclosed for use in additive manufacturing. The continuous reinforcement may include a plurality of continuous primary fibers oriented in a general axial direction of the continuous reinforcement. The continuous reinforcement may also include a plurality of secondary fibers interspersed with the plurality of continuous primary fibers and oriented generally orthogonal to the plurality of continuous primary fibers.