Abstract: In part, the disclosure relates to systems and methods of layer-by-layer assembly of composite structures such as for parts or workpieces. Various additive and subtractive processes can be used. In various embodiments, prepreg tapes that include continuous reinforcing fibers are used. In one aspect, a system that includes printer heads is provided. The printer heads may, in some embodiments, be used for manufacturing high quality continuous fiber reinforced structural parts. In some embodiments, the system includes a first printer head configured to lay down tape (e.g., a thermoplastic tape that includes reinforcing fibers).

Abstract: In part, the disclosure relates to an applicator management system for fabricating 3D parts. The system includes a first applicator; a housing; a mount, wherein the mount is moveable in one or more directions within the housing; a build plate disposed within the housing, wherein position of build plate is adjustable in one or more directions; and an applicator changer coupled to the moveable mount; wherein the applicator changer includes a first interface to operatively engage the first applicator and a second applicator. In part, the disclosure relates to the use of magnetic coupling or docking system.

Abstract: In one aspect, the disclosure relates to a method of fabricating a three-dimensional object. The method includes transporting a first material, in a first state, the first material comprising a thermoplastic matrix and M reinforcing fibers, wherein the first material has a first cross-sectional profile; depositing, heating, and consolidating a segment of the first material such that it is placed in a second state having a second cross-sectional profile; and repeating the foregoing steps until a unitary composite object has been formed by M segments of the first material. In one embodiment, consolidation is performed to achieve a porosity of less than about 2%. In one embodiment, a ratio of volume of the reinforcing fibers to matrix first material ranges from about 0.5 to about 0.7.

Abstract: A method and system for manufacturing a part where a three-dimensional support is printed, using a fused filament fabrication-based print head (XX), wherein the support comprises layers of fused polymer filament; and heating one or more segments of prepreg thermoplastic tape (105), using a heating element disposed in a tape deposition head (100); depositing one or more heated segments of prepreg thermoplastic tape on the three-dimensional support in one or more directions; compacting with a roller (125), the one or more segments of prepreg thermoplastic tape such that the one or more segments conform to the support; and repeating depositing and compacting steps and periodically changing the one or more directions until a fiber-reinforced multi-layer part comprising one or more surfaces is formed, wherein at least one surface of the one or more surfaces is defined by the support.