Abstract: A system for additively manufacturing an object comprises feedstock-line supply, delivery guide, and curing mechanism. The feedstock-line supply dispenses a feedstock line that comprises elongate filaments, a resin that covers the elongate filaments, and at least one optical modifier that is interspersed among the elongate filaments. The delivery guide is movable relative to a surface, receives the feedstock line, and deposits it along a print path. The curing mechanism is directs electromagnetic radiation at the exterior surface of the feedstock line after it is deposited along the print path. When the electromagnetic radiation strikes the outer surface of at least one optical modifier, the optical modifier causes the electromagnetic radiation to irradiate, in the interior volume of the feedstock line, the resin that, due at least in part to the elongate filaments, is not directly accessible to the electromagnetic radiation, incident on the exterior surface of the feedstock line.

Abstract: A feedstock line comprises elongate filaments, a resin, and a full-length optical waveguide, comprising a full-length optical core. The full-length optical waveguide is configured such that when electromagnetic radiation enters the full-length optical core via at least one of a first full-length-optical-core end face, a second full-length-optical-core end face, or a full-length peripheral surface that extends between the first full-length-optical-core end face and the second full-length-optical-core end face, at least a portion of the electromagnetic radiation exits the full-length optical core via the full-length peripheral surface to irradiate, in an interior volume of the feedstock line, the resin that, due at least in part to the elongate filaments, is not directly accessible to the electromagnetic radiation, incident on the exterior surface of the feedstock line.

Abstract: A feedstock line comprises elongate filaments, a resin, and a full-length optical waveguide, comprising a full-length optical core. The full-length optical waveguide is configured such that when electromagnetic radiation enters the full-length optical core via at least one of a first full-length-optical-core end face, a second full-length-optical-core end face, or a full-length peripheral surface that extends between the first full-length-optical-core end face and the second full-length-optical-core end face, at least a portion of the electromagnetic radiation exits the full-length optical core via the full-length peripheral surface to irradiate, in an interior volume of the feedstock line, the resin that, due at least in part to the elongate filaments, is not directly accessible to the electromagnetic radiation, incident on the exterior surface of the feedstock line.

Abstract: A feedstock line comprises elongate filaments, a resin, and a full-length optical waveguide, comprising a full-length optical core. The full-length optical waveguide is configured such that when electromagnetic radiation enters the full-length optical core via at least one of a first full-length-optical-core end face, a second full-length-optical-core end face, or a full-length peripheral surface that extends between the first full-length-optical-core end face and the second full-length-optical-core end face, at least a portion of the electromagnetic radiation exits the full-length optical core via the full-length peripheral surface to irradiate, in an interior volume of the feedstock line, the resin that, due at least in part to the elongate filaments, is not directly accessible to the electromagnetic radiation, incident on the exterior surface of the feedstock line.

Abstract: Systems and methods for additively manufacturing composite parts are disclosed. Methods comprise combining a plurality of pre-consolidated tows to define a macro tow and dispensing the macro tow in three dimensions to define the composite part. Each pre-consolidated tow comprises a fiber tow within a non-liquid binding matrix. The combining comprises actively altering a shape and/or size of a cross-sectional profile of the macro tow along a length of the macro tow as it is being defined.

Abstract: A system for creating a feedstock line for additive manufacturing of an object comprises a prepreg-tow supply, a prepreg-tow separator, an optical-direction-modifier supply, a combiner, and at least one heater. The prepreg-tow supply dispenses a precursor prepreg tow, comprising elongate filaments and resin. The prepreg-tow separator separates the precursor prepreg tow into individual elongate filaments at least partially covered with the resin. The optical-direction-modifier supply dispenses optical direction modifiers to the elongate filaments. When electromagnetic radiation strikes the outer surface of the optical direction modifiers, at least a portion of the electromagnetic radiation departs the outer surface at an angle. The combiner combines the elongate filaments and the optical direction modifiers into a derivative prepreg tow. At least the one heater heats the resin to cause wet-out of the optical direction modifiers and the elongate filaments in the derivative prepreg tow by the resin.

Abstract: Systems and methods for additively manufacturing composite parts are disclosed. Systems comprise at least a feedstock source and a feed mechanism. The feedstock source comprises a plurality of pre-consolidated tows, with each pre-consolidated tow comprising a fiber tow within a non-liquid binding matrix. In some systems, a tow combiner receives at least a subset of the plurality of pre-consolidated tows from the feedstock source and combines the subset of the plurality of pre-consolidated tows to define a macro tow. The feed mechanism moves the subset of the plurality of pre-consolidated tows from the feedstock source and into the tow combiner and moves the macro tow from the tow combiner. Methods according to the present disclosure comprise combining a plurality of pre-consolidated tows to define a macro tow, and dispensing the macro tow in three dimensions to define a composite part.

Abstract: A system (700) for additively manufacturing an object (136) comprises feedstock-line supply (702), delivery guide (704), and curing mechanism (706). The feedstock-line supply (702) dispenses a feedstock line (100) that comprises elongate fibers (104), a resin (124) that covers the elongate fibers (104), and at least one optical modifier (123) that is interspersed among the elongate filaments (104). The delivery guide (704) is movable relative to a surface (708), receives the feedstock line (100), and deposits it along a print path (705). The curing mechanism (706) is directs electromagnetic radiation (118) at the exterior surface (180) of the feedstock line (100) after it is deposited along the print path (705).

Abstract: A feedstock line (100) comprises elongate filaments (104), a resin (124), and a full-length optical waveguide (102), comprising a full-length optical core (110). The full-length optical waveguide (102) is configured such that when electromagnetic radiation (118) enters the full-length optical core (110) via at least one of a first full-length-optical-core end face (112), a second full-length-optical-core end face (114), or a full-length peripheral surface (116) that extends between the first full-length-optical-core end face (112) and the second full-length-optical-core end face (114), at least a portion of the electromagnetic radiation (118) exits the full-length optical core (110) via the full-length peripheral surface (116) to irradiate, in an interior volume (182) of the feedstock line (100), the resin (124) that, due at least in part to the elongate filaments (104), is not directly accessible to the electromagnetic radiation (118), incident on the exterior surface (180) of the feedstock line (100).

Abstract: A feedstock line (100) comprises elongate filaments (104), a resin (124), and optical direction modifiers (123). The resin (124) covers the elongate filaments (104). The optical direction modifiers (123) are covered by the resin (124) and are interspersed among the elongate filaments (104). Each of the optical direction modifiers (123) has an outer surface (184). Each of the optical direction modifiers (123) is configured such that when electromagnetic radiation (118) strikes the outer surface (184) from a first direction, at least a portion of the electromagnetic radiation (118) departs the outer surface (184) in a second direction that is at an angle to the first direction to irradiate, in the interior volume of the feedstock line (100), the resin (124) that, due at least in part to the elongate filaments (104), is not directly accessible to the electromagnetic radiation (118), incident on the exterior surface of the feedstock line.

Abstract: A feedstock line (100) comprises elongate filaments (104), a resin (124), and a full-length optical waveguide (102), comprising a full-length optical core (110). The full-length optical waveguide (102) is configured such that when electromagnetic radiation (118) enters the full-length optical core (110) via at least one of a first full-length-optical-core end face (112), a second full-length-optical-core end face (114), or a full-length peripheral surface (116) that extends between the first full-length-optical-core end face (112) and the second full-length-optical-core end face (114), at least a portion of the electromagnetic radiation (118) exits the full-length optical core (110) via the full-length peripheral surface (116) to irradiate, in an interior volume (182) of the feedstock line (100), the resin (124) that, due at least in part to the elongate filaments (104), is not directly accessible to the electromagnetic radiation (118), incident on the exterior surface (180) of the feedstock line (100).

Abstract: A feedstock line (100) comprises elongate filaments (104), a resin (124), and a full-length optical waveguide (102), comprising a full-length optical core (110). The full-length optical waveguide (102) is configured such that when electromagnetic radiation (118) enters the full-length optical core (110) via at least one of a first full-length-optical-core end face (112), a second full-length-optical-core end face (114), or a full-length peripheral surface (116) that extends between the first full-length-optical-core end face (112) and the second full-length-optical-core end face (114), at least a portion of the electromagnetic radiation (118) exits the full-length optical core (110) via the full-length peripheral surface (116) to irradiate, in an interior volume (182) of the feedstock line (100), the resin (124) that, due at least in part to the elongate filaments (104), is not directly accessible to the electromagnetic radiation (118), incident on the exterior surface (180) of the feedstock line (100).

Abstract: A feedstock line comprises elongate filaments, a resin, and optical direction modifiers. The resin covers the elongate filaments. The optical direction modifiers are covered by the resin and are interspersed among the elongate filaments. Each of the optical direction modifiers has an outer surface. Each of the optical direction modifiers is configured such that when electromagnetic radiation strikes the outer surface from a first direction, at least a portion of the electromagnetic radiation departs the outer surface in a second direction that is at an angle to the first direction to irradiate, in the interior volume of the feedstock line, the resin that, due at least in part to the elongate filaments, is not directly accessible to the electromagnetic radiation, incident on the exterior surface of the feedstock line.

Abstract: Automated assembly systems and methods are configured to automatically insert components into grommets. The systems include a component insertion sub-system configured to insert first components into first cavities of a first grommet, an imaging sub-system configured to acquire images of the first grommet, and a grommet shift determination sub-system in communication with the component insertion sub-system and the imaging sub-system. The grommet shift determination sub-system is configured to compare at least two images of the first grommet acquired by the imaging sub-system to determine distance changes between the first cavities in response to one or more of the first components being inserted into one or more of the first cavities, and generate an insertion map that accounts for the distance changes.

Abstract: A system (100) for additively manufacturing an object (102) comprises a fiber supply (122) that dispenses elongate fibers (108), a resin supply (124) that applies a resin (110) to the elongate fibers (108) to create a feedstock line (106) with the resin (110) in a first non-rigid uncured state, a rigidizing mechanism (112) that transforms the resin (110) from the first non-rigid uncured state to a rigid uncured state, a delivery guide (116) that deposits the feedstock line (106) along a print path (114), a feed mechanism (126) that feeds the feedstock line (106) through the delivery guide (116), a de-rigidizing mechanism (118) that transforms the resin (110) from the rigid uncured state to a second non-rigid uncured state, and a curing mechanism (120) that transforms the resin (110) from the second non-rigid uncured state to an at least partially cured state.

Abstract: A system (300) for additively manufacturing an object (102) comprises a source (302) of a feedstock line (106), a rigidizing mechanism (112) that receives the feedstock line (106) from the source (302) and transforms the resin (110) from a first at least partially uncured state to a rigid at least partially uncured state, a delivery guide (116) that deposits the feedstock line (106) along a print path (114), a feed mechanism (126) that feeds the feedstock line (106) through the delivery guide (116), a de-rigidizing mechanism (118) that transforms the resin (110) from the rigid at least partially uncured state to a second at least partially uncured state, and a curing mechanism (120) that transforms the resin (110) from the second at least partially uncured state to an at least partially cured state.

Abstract: A feedstock line (100) for additively manufacturing an object (108). The feedstock line (100) has a length and comprises a continuous flexible line (102). The continuous flexible line (102) has a peripheral surface (104). The feedstock line (100) also comprises a covering (106). The covering (106) is releasably coupled to the peripheral surface (104) of the continuous flexible line (102).

Abstract: A feedstock line comprises elongate filaments, a resin, and optical direction modifiers. The resin covers the elongate filaments. The optical direction modifiers are covered by the resin and are interspersed among the elongate filaments. Each of the optical direction modifiers has an outer surface. Each of the optical direction modifiers is configured such that when electromagnetic radiation strikes the outer surface from a first direction, at least a portion of the electromagnetic radiation departs the outer surface in a second direction that is at an angle to the first direction to irradiate, in the interior volume of the feedstock line, the resin that, due at least in part to the elongate filaments, is not directly accessible to the electromagnetic radiation, incident on the exterior surface of the feedstock line.

Abstract: Systems for cure control of additive manufacturing comprise a build volume, a curing energy source, and a controller. The curing energy source is configured to actively deliver curing energy to discrete sections of a part as it is being additively manufactured. The controller is programmed to direct delivery of curing energy to impart desired cure properties to the discrete sections and/or according to predetermined cure profiles for the discrete sections. Methods of additively manufacturing a part comprise additively building a part from a feedstock material, and actively curing discrete sections of the part as it is being additively built to impart desired cure properties to the part and/or desired cure profiles to the part.

Abstract: Systems for additive manufacturing comprise a delivery guide configured to dispense a curable material to additively manufacture a part in sequential layers of the curable material, and a source of curing energy configured to direct the curing energy to a discrete region of the curable material forward of or at a location where a subsequent layer of the curable material is dispensed from the delivery guide against a preceding layer of the curable material to cure together the subsequent layer and the preceding layer. Methods of additively manufacturing comprise dispensing a subsequent layer of a curable material against a preceding layer of the curable material, and concurrently with the dispensing, directing curing energy to a discrete region of the curable material to cure together the subsequent layer and the preceding layer.