System and method for additively manufacturing composite wiring harness

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.

What is claimed is: 
     
         1 . A method of additively manufacturing a composite wiring harness, comprising:
 directing a plurality of conductors through a print head;   directing at least one reinforcement through the print head;   coating at least one of the plurality of conductors and the at least one reinforcement with a matrix material;   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.   
     
     
         2 . The method of  claim 1 , wherein discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material from the print head includes:
 first discharging only the at least one reinforcement with the matrix material to form a portion of the sheath;   discharging only the plurality of conductors against the portion of the sheath; and   discharging only the reinforcement with the matrix material against the plurality of conductors to close off the sheath around the plurality of conductors.   
     
     
         3 . The method of  claim 1 , wherein discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material from the print head includes discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material directly onto a machine for which the composite harness will conduct at least one of power and signals. 
     
     
         4 . The method of  claim 1 , wherein discharging the at least one of the plurality of conductors and the at least one reinforcement with the matrix material from the print head includes:
 connecting the at least one of the plurality of conductors and the at least one reinforcement to an anchor; and   moving the print head away from the anchor to cause the at least one of the plurality of conductors and the at least one reinforcement to be pulled from the print head.   
     
     
         5 . The method of  claim 4 , wherein the anchor is a connector; and the method further includes removably coupling the connector with a mating connector affixed to a print bed prior to moving the print head away from the anchor. 
     
     
         6 . The method of  claim 1 , further including embedding a functional element into at least one of the plurality of conductors prior to directing the plurality of conductors through the print head. 
     
     
         7 . The method of  claim 6 , wherein the functional element is one of an LED, a resistor, a capacitor, a battery, a switch, a fuse, and a filter. 
     
     
         8 . The method of  claim 1 , further including varying at least one of a type and an amount of at least one of the matrix material and the at least one reinforcement along a length of the composite wiring harness. 
     
     
         9 . The method of  claim 8 , wherein varying at least one of a type and an amount of at least one of the matrix material and the at least one reinforcement includes selectively making the plurality of conductors visible through the sheath. 
     
     
         10 . The method of  claim 8 , wherein varying at least one of a type and an amount of at least one of the matrix material and the at least one reinforcement includes selectively adjusting electromagnetic field shielding along a length of the composite wiring harness. 
     
     
         11 . The method of  claim 8 , wherein varying at least one of a type and an amount of at least one of the matrix material and the at least one reinforcement includes selectively adjusting a flexibility of the matrix material along the length of the composite wiring harness. 
     
     
         12 . The method of  claim 1 , further including forming a hardpoint passing through the sheath that is devoid of the at least one reinforcement and the plurality of conductors. 
     
     
         13 . The method of  claim 12 , wherein the hardpoint passes through a wall of the sheath in a direction generally orthogonal to an axis of the composite wiring harness. 
     
     
         14 . The method of  claim 1 , further including moving the print head during the exposing, such that an axis of the composite wiring harness is three-dimensional. 
     
     
         15 . The method of  claim 1 , wherein the plurality of conductors includes at least one fiber optic. 
     
     
         16 . The method of  claim 1 , wherein exposing the matrix material during discharging to a cure energy includes exposing the matrix material to UV light. 
     
     
         17 . A method of additively manufacturing a composite wiring harness, comprising:
 directing a conductor through a print head;   coating the conductor with a matrix material; and   discharging the conductor with the matrix material from the print head directly onto a machine for which the composite harness will conduct at least one of power and signals.   
     
     
         18 . The method of  claim 17 , wherein coating the conductor with the matrix material includes coating the conductor with a liquid inside of the print head. 
     
     
         19 . The method of  claim 17 , further including exposing the matrix material during discharging to a cure energy to cause hardening of the matrix material. 
     
     
         20 . The method of  claim 19 , further including moving the print head during the exposing, such that an axis of the composite wiring harness is three-dimensional.