Abstract: A system comprises a delivery guide movable relative to a surface. The delivery guide is configured to deposit a continuous flexible line along a print path that is stationary relative to the surface. The system further comprises a vessel, configured to hold a volume of a liquid photopolymer resin and to apply a quantity of the liquid photopolymer resin to the non-resin component to create the continuous flexible line. The system further comprises a feed mechanism, configured to pull the non-resin component through the vessel and to push the continuous flexible line out of the delivery guide. The system further comprises a source of curing energy. The source is configured to deliver the curing energy at least to a portion of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide.

Abstract: A system for additively manufacturing a composite part comprises a delivery guide, movable relative to a surface. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting-resin component. The thermosetting-resin component comprises a first part and a second part. The system further comprises a first resin-part applicator, configured to apply a first quantity of the first part to the non-resin component, and a second resin-part applicator, configured to apply a second quantity of the second part to the first quantity of the first part of a thermosetting resin, applied to the non-resin component. The system also comprises a feed mechanism, configured to pull the non-resin component through the first resin-part applicator and the second resin-part applicator, and to push the continuous flexible line out of the delivery guide.

Abstract: A method of additively manufacturing a composite part is disclosed. The method comprises depositing a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting resin component that is not fully cured. The method further comprises, while advancing the continuous flexible line toward the print path, delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line.

Abstract: A method of additively manufacturing a composite part is disclosed. The method comprises pushing a continuous flexible line through a delivery guide. The continuous flexible line comprises a non-resin component and a thermosetting-epoxy-resin component that is partially cured. The method also comprises depositing, via the delivery guide, a segment of the continuous flexible line along a print path. The method further comprises maintaining the thermosetting-epoxy-resin component of at least the continuous flexible line being pushed through the delivery guide below a threshold temperature prior to depositing the segment of the continuous flexible line along the print path.

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: A method of additively manufacturing a composite part comprises applying a liquid photopolymer resin to a non-resin component to create a continuous flexible line by pulling the non-resin component through a vessel, containing a volume of the liquid photopolymer resin. The continuous flexible line comprises the non-resin component and a photopolymer-resin component that comprises at least some of the liquid photopolymer resin applied to the non-resin component. The method further comprises routing the continuous flexible line into a delivery guide, pushing the continuous flexible line out of the delivery guide, depositing, via the delivery guide, a segment of the continuous flexible line along a print path, and delivering curing energy at least to a portion of the segment of the continuous flexible line.

Abstract: A method of additively manufacturing a composite part is disclosed. The method comprises depositing, via a delivery guide, a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting-epoxy-resin component that is partially cured. The method also comprises maintaining the thermosetting-epoxy-resin component of at least the continuous flexible line being advanced toward the print path via the delivery guide below a threshold temperature. The method further comprises delivering a predetermined or actively determined amount of curing energy to the segment of the continuous flexible line at a controlled rate while advancing the continuous flexible line toward the print path to at least partially cure the segment of the continuous flexible line.

Abstract: A method of additively manufacturing a composite part comprises applying a first quantity of a first part of a thermosetting resin to a first element of a non-resin component by pulling the first element through a first resin-part applicator and applying a second quantity of a second part of the thermosetting resin to a second element of the non-resin component by pulling the second element through a second resin-part applicator. The method also comprises combining the first element with the first quantity of first part and the second element with the second quantity of second part, to create a continuous flexible line. The method additionally comprises routing the continuous flexible line into a delivery guide and depositing, via the delivery guide, a segment of the continuous flexible line along a print path.

Abstract: A method of additively manufacturing a composite part comprises applying a thermosetting resin to a non-resin component to create a continuous flexible line by pulling a non-resin component through a first resin-part applicator, in which a first quantity of a first part of the thermosetting resin is applied to the non-resin component, and by pulling a non-resin component through a second resin-part applicator, in which a second quantity of a second part of the thermosetting resin is applied to at least a portion of the first quantity of the first part of the thermosetting resin, applied to the non-resin component. The method further comprises routing the continuous flexible line into a delivery guide and depositing, via the delivery guide, a segment of the continuous flexible line along a print path.

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: An apparatus (110) for shaping an extrudable material (140) comprises a sleeve (126), comprising a first sleeve end (186), a sleeve inlet (148) at the first sleeve end (186), a second sleeve end (188), opposite the first sleeve end (186), and a sleeve outlet (132) at the second sleeve end (188). The extrudable material (140) enters the sleeve (126) through the sleeve inlet (148) and exits the sleeve (126) through the sleeve outlet (132). The apparatus (110) further comprises an actuation mechanism (172), selectively operable to change at least one of a size or a shape of the sleeve outlet (132). The sleeve (126) is sufficiently flexible to enable the actuation mechanism (172) to change at least one of the size or the shape of the sleeve outlet (132). The sleeve (126) is insufficiently stretchable to enable the actuation mechanism (172) to stretch the sleeve (126).

Abstract: A method of additively manufacturing composite part comprises depositing a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and further comprises a photopolymer-resin component that is uncured. The method further comprises delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate while advancing the continuous flexible line toward the print path and after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line.

Abstract: A method of additively manufacturing a composite part comprises applying a photopolymer resin to a non-resin component while pushing a continuous flexible line through a delivery assembly. The continuous flexible line comprises the non-resin component and a photopolymer-resin component that comprises at least some of the photopolymer resin applied to the non-resin component. The method also comprises depositing, via the delivery assembly, a segment of the continuous flexible line along a print path. The method further comprises delivering curing energy to at least a portion of the segment of the continuous flexible line deposited along the print path.

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 method of additively manufacturing a composite part comprises depositing a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a photopolymer-resin component that is partially cured. The method also comprises delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate while advancing the continuous flexible line toward the print path and after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line.

Abstract: A method of additively manufacturing a composite part is disclosed. The method comprises applying a thermosetting resin to a non-resin component of a continuous flexible line while pushing the non-resin component through a delivery guide and pushing the continuous flexible line out of the delivery guide. The continuous flexible line further comprises a thermosetting resin component that comprises at least some of the thermosetting resin applied to the non-resin component. The method further comprises depositing, via the delivery guide, a segment of the continuous flexible line along the print path.

Abstract: A method of additively manufacturing a composite part comprises pushing a continuous flexible line through a delivery guide. The continuous flexible line comprises a non-resin component and a photopolymer-resin component that is partially cured. The method also comprises depositing, via the delivery guide, a segment of the continuous flexible line along a print path. Additionally, the method comprises delivering curing energy at least to a portion of the segment of the continuous flexible line deposited along the print path.

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: A system for additively manufacturing a composite part is disclosed. The system comprises a housing and a nozzle. The nozzle is supported by the housing. The nozzle comprises an outlet, sized to dispense a continuous flexible line. The continuous flexible line comprises a non-resin component and a photopolymer-resin component. The system also comprises a feed mechanism, supported within the housing. The feed mechanism is configured to push the continuous flexible line out of the outlet of the nozzle. The system further comprises a light source, supported by the housing. The light source is configured to deliver a light beam to the continuous flexible line after the continuous flexible line exits the outlet of the nozzle to at least partially cure the photopolymer-resin component of the continuous flexible line.