Abstract: Additive manufacturing systems and methods having an extrusion head with a nozzle. The nozzle extrudes a composite material from an orifice of the nozzle to form a layer of a component. The composite material has at least a matrix material and a reinforcing material. The nozzle extrudes the matrix and reinforcing materials from the orifice simultaneously. The width and height of the orifice are adjustable to control the width and thickness of the layer extruded therefrom. The width and thickness of the layer are the same as the width and height, respectively, of the nozzle orifice, while the nozzle is extruding the composite material through the orifice. The width and height of the nozzle orifice are perpendicular to each other and transverse to an extrusion direction from the nozzle orifice. A majority of a surface area of the reinforcing material is encapsulated within the matrix material after being dispensed from the nozzle.

Abstract: A system for making a finished component having a three-dimensional (3D) reinforcement integrally formed within a cured additive manufacturing fluid via an additive manufacturing process. The system includes a transport having the 3D reinforcement attached thereto, the transport being used to at least partially immerse the 3D reinforcement within the additive manufacturing fluid in an uncured state; an energy source that emits energy, which changes the additive manufacturing fluid from an uncured state to a cured state, to a focal point; and a controller that controls a position of the focal point to pass over at least a portion of an outer surface of the 3D reinforcement according to a curing pattern, changing the additive manufacturing fluid from the uncured state to the cured state on the portion of the outer surface of the 3D reinforcement defined by the curing pattern as the curing pattern is executed by the controller.

Abstract: A system for making a component having a plurality of layers sequentially deposited via additive manufacturing has a nozzle and a print controller. The nozzle has an orifice. The print controller defines a print pattern for the nozzle for each layer of the component. The print pattern defines a print order in which filaments are deposited from the nozzle to form one of the plurality of layers of the component. A cutter at the orifice of the nozzle is used to cut the filament as required according to the print pattern. The nozzle moves according to the print pattern for the layer of the component being formed and simultaneously coextrude an elastomeric matrix material and a reinforcing material from the orifice of the nozzle as one of the filaments, such that the reinforcing material is entirely internal to the elastomeric matrix material.

Abstract: Additive manufacturing systems and methods having an extrusion head with a nozzle. The nozzle extrudes a composite material from an orifice of the nozzle to form a layer of a component. The composite material has at least a matrix material and a reinforcing material. The nozzle extrudes the matrix and reinforcing materials from the orifice simultaneously. The width and height of the orifice are adjustable to control the width and thickness of the layer extruded therefrom. The width and thickness of the layer are the same as the width and height, respectively, of the nozzle orifice, while the nozzle is extruding the composite material through the orifice. The width and height of the nozzle orifice are perpendicular to each other and transverse to an extrusion direction from the nozzle orifice. A majority of a surface area of the reinforcing material is encapsulated within the matrix material after being dispensed from the nozzle.