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 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 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 method is disclosed for additively manufacturing a composite structure. The method may include coating a continuous strand with a matrix, discharging a composite tubular structure made from the coated continuous strand, and exposing the matrix in the composite tubular structure to light to cure the matrix during discharging. The method may also include depositing a material layer onto an internal surface of the composite tubular structure as the composite tubular structure is being discharged, and wiping a squeegee over the material layer.

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: 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 print head is disclosed for use in an additive manufacturing system. The print head may include a first end configured to receive a continuous reinforcement, and a second end configure to discharge the continuous reinforcement at least partially coated in a matrix. The print head may also include a cutting module disposed between the first and second ends. The cutting module may include a blade, an anvil, and an actuator operatively connected to at least one of the blade and the anvil.

Abstract: A print head is disclosed for use in an additive manufacturing system. The print head may include a discharge outlet configured to discharge a continuous reinforcement, and an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge. The print head may also include a cure enhancer configured to soften the solid film after discharge.

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 sporting equipment is disclosed. The sporting equipment may include a barrel, an action connected to a base end of the barrel, and a stock connected to the action opposite the barrel. At least two of the barrel, the action, and the stock are fabricated from a plurality of fibers.

Abstract: A head is disclosed for use with an additive manufacturing system. The head may include a matrix reservoir, and a nozzle fluidly connected to the matrix reservoir and configured to discharge a composite material into a feature of an existing component. The head may also include a guide operatively connected to the nozzle and configured to detect a location of the feature.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a head having a matrix reservoir, a nozzle fluidly connected to the matrix reservoir and configured to discharge a composite material into a feature of an existing component. a guide configured to detect a location of the feature, and a cure enhancer configured to expose composite material discharging from the nozzle to a cure energy. The system may also include a support configured to move the head in multiple dimensions, and a controller in communication with the cure enhancer and the support. The controller may be configured to cause the support to move the head during discharge of the composite material into the feature based on the detected location of the feature.

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 nozzle is disclosed for use with an additive manufacturing system. The nozzle may include a first channel fluidly connectable to a matrix reservoir and configured to discharge a liquid matrix received from the matrix reservoir. The nozzle may also include a second channel operatively connected to the first channel configured to discharge a reinforcement into a bed of the liquid matrix discharged by the first channel.

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: A system is disclosed for use in manufacturing a composite structure. The system may include a support configured to move in a plurality of directions during manufacturing of the composite structure, and a head coupled to the support. The head may have a housing that is configured to receive a liquid matrix and at least one continuous fiber and configured to discharge a tubular structure. The head may also have a nozzle operatively connected to the housing and configured to deposit a material layer onto a surface of the tubular structure as the tubular structure is discharging from the housing, and a squeegee associated with the nozzle and configured to wipe over the material layer. The head may further have a first cure enhancer operatively connected to the housing and configured to cure the liquid matrix in the tubular structure during discharge, and a second cure enhancer configured to cure the material layer deposited by the nozzle.

Abstract: An additive manufacturing method is disclosed. The method may include directing into a print head a reinforcement having a continuous axial core and integral branches extending radially outward from the continuous axial core. The method may also include coating the reinforcement in a matrix, and softening a portion of a track of the coated reinforcement that was previously discharged from the print head. The method may further include discharging from the print head a track of the coated reinforcement adjacent the previously discharged track of the coated reinforcement, such that cross-bonding of the integral branches occurs between the discharging track of the coated reinforcement and the softened portion of the previously discharged track of the coated reinforcement.

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.