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 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, including a continuous fiber and a matrix at least partially coating the continuous fiber. The processor may also be configured to execute the computer-executable instructions to monitor an energy level within the continuous fiber during discharging, to make a determination that the continuous fiber has lost continuity based on a reduction in the energy level, and to selectively interrupt the discharging based on the determination.

Abstract: A print head is disclosed for use with an additive manufacturing system. The print head may include a nozzle having a base end, a tip end, and a cylindrical passage extending from the base end to the tip end. The print head may also include a compactor located at least partially inside of the nozzle at the tip end.

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 determine a plurality of tension vectors to be generated within the structure, and to generate a plan for manufacturing the structure. The plan may include tool paths that arrange continuous fibers within the structure to generate the plurality of tension vectors. The processor may also be configured to execute the computer-executable instructions to cause the additive manufacturing machine to follow the plan and manufacture the structure.

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 make a determination associated with the structure being a performance-critical part and, based on the determination, selectively implement a first slicing technique or a second slicing technique to divide a virtual model of the structure into a plurality of planes. The processor may be further configured to execute the computer-executable instructions to cause the additive manufacturing machine to deposit composite material in layers corresponding to the plurality of planes.

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 determine if a tool path to be followed by the additive manufacturing machine during manufacture of the structure is located in free-space or on top of another tool path. When the tool path is located in free-space, the processor may be further configured to execute the computer-executable instructions to make a determination regarding a curvature of the tool path, and to selectively cause the additive manufacturing machine to fabricate a support for the tool path based on the determination.

Abstract: An additive manufacturing system may include a head configured to discharge a matrix-coated reinforcement, a support configured to move the head during discharging, and a cure enhancer configured to cure the matrix as the matrix-coated reinforcement discharges from the head. The additive manufacturing system may also include a controller in communication with the head, the support, and the cure enhancer. The controller may be configured to receive specifications for a structure to be fabricated, and to determine an anchor point from which the matrix-coated reinforcement will be pulled during fabrication of the structure. The controller may also be configured to regulate operation of the head, the support, and the cure enhancer to manufacture the structure and the anchor point.

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 for additively manufacturing a composite structure is disclosed. The system may include a print head configured to discharge a matrix-coated reinforcement, and a support configured to move the print head in multiple dimensions during discharging of the matrix-coated reinforcement. The system may further include at least one cure enhancer located offboard the print head, and a controller in communication with the support and the at least one cure enhancer. The controller may be configured to selectively activate the at least one cure enhancer to expose the matrix-coated reinforcement to a cure energy during discharging of the matrix-coated reinforcement.

Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head configured to wet a continuous reinforcement with a liquid matrix and discharge the wetted continuous reinforcement. The print head may be operatively connected to and moveable by the support during discharge. The additive manufacturing system may also include a matrix control mechanism configured to selectively adjust an amount of matrix on the continuous reinforcement being discharged from the print head.

Abstract: A head is disclosed for use with an additive manufacturing system. The head may include a housing, and a matrix reservoir disposed inside of the housing. The head may also include at least one roller located inside of the housing and configured to engage at least one of a ribbon and a sheet of reinforcement passing through the head. The head may further include a nozzle fluidly connected to the matrix reservoir, and a cure enhancer located outside of the housing and adjacent the nozzle.

Abstract: A vehicle body may have an internal skeleton forming a wing shape, and a skin formed over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. The plurality of continuous fibers may curve from a base end near a fore/aft center of the wing shape outward toward leading and trailing edges of the wing shape at a tip end.

Abstract: A head is disclosed for use with an additive manufacturing system. The head may include a matrix reservoir, and a plurality of nozzles simultaneously fluidly connected to the matrix reservoir. The head may also include at least one hinge connecting the plurality of nozzles.

Abstract: A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.

Abstract: A print head is disclosed for use with an additive manufacturing system. The print head may include a matrix reservoir, and a nozzle base connected to an end of the matrix reservoir. The nozzle base may have a plurality of attachment features formed within an exposed surface. The print head may further include a plurality of available dies separately connectable to the nozzle base via the plurality of attachment features. Attachment of the plurality of available dies to the nozzle base may establish fluid communication with the matrix reservoir.

Abstract: A structure is disclosed that is additively manufactured. The structure may include at least one continuous reinforcement, and a healing matrix associated with the at least one continuous reinforcement. Wherein a cure energy is applied to the at least one continuous reinforcement at a time of failure, the healing matrix is caused to cure and shore up the at least one 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 sporting equipment is disclosed. The sporting equipment may include a harness, and a protective plate. The protective plate may be integrally formed with the harness from a plurality of fibers that are continuous from the harness into the protective plate.

Abstract: A system is disclosed for use in fabricating a custom vehicle. The system may include an additive manufacturing machine, and at least one computing device operatively connected to the additive manufacturing machine. The at least one computing device includes a memory having computer-executable instructions stored thereon and a processor configured to execute the computer-executable instructions to receive from a user a selection of available components that can be built into the custom vehicle, and to generate a unique model of the custom vehicle based on the selection. The processor is further configured to execute the computer-executable instructions to generate code associated with the unique model, and to direct the code to the additive manufacturing machine, causing the additive manufacturing machine to additively manufacture at least a portion of the custom vehicle.

Abstract: A vehicle body may have an internal skeleton, and a skin formed over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. At least one of the plurality of continuous fibers is in tension and has differing levels of tension along its length.