System for additive manufacturing

Abstract

A system is disclosed for additive manufacturing of a composite structure. The system may include an outlet through which a composite material is discharged, and a nose that is a component separate from the outlet and located at a distal end of the outlet. The nose may be biased axially relative to the outlet, from a retracted position to an extended position. The nose extends axially past the distal end of the outlet in the extended position.

What is claimed is: 
     
         1 . A system for additively manufacturing, comprising:
 an outlet through which a composite material is discharged; and   a nose that is a component separate from the outlet and located at a distal end of the outlet, wherein:
 the nose is biased axially relative to the outlet, from a retracted position to an extended position; and 
 the nose extends axially past the distal end of the outlet in the extended position. 
   
     
     
         2 . The system of  claim 1 , further including at least one spring configured to bias the nose axially relative to the outlet. 
     
     
         3 . The system of  claim 1 , further including a matrix reservoir located at a side of the outlet opposite the nose, the matrix reservoir configured to wet a continuous reinforcement with a matrix to form the composite material. 
     
     
         4 . The system of  claim 3 , further including a cure enhancer configured to expose the matrix in the composite material to a cure energy after the nose has passed over the composite material. 
     
     
         5 . The system of  claim 4 , further including a support configured to move the matrix reservoir, the outlet, and nose together. 
     
     
         6 . The system of  claim 5 , further including a controller in communication with the cure enhancer and the support, the controller being configured to coordinate operations of the support and the cure enhancer based on specifications for a structure to be manufactured from the composite material. 
     
     
         7 . The system of  claim 5 , wherein the support is located at a side of the matrix reservoir opposite the outlet. 
     
     
         8 . The system of  claim 1 , wherein the nose annularly surrounds the distal end of the outlet. 
     
     
         9 . The system of  claim 1 , wherein the nose extends axially from the distal end of the outlet. 
     
     
         10 . The system of  claim 1 , further including a coating on an outer end surface of the nose, the coating configured to inhibit the composite material from sticking to the nose. 
     
     
         11 . The system of  claim 1 , wherein a material forming the outlet is harder than a material forming the nose. 
     
     
         12 . The system of  claim 11 , wherein:
 the material forming the outlet is one of stainless steel or aluminum; and   the material forming the nose is a polymer.   
     
     
         13 . The system of  claim 1 , wherein during operation, an end surface of the nose is generally flush with an end surface of the outlet. 
     
     
         14 . The system of  claim 1 , further including a resurfacer configured to restore an outer profile of the nose. 
     
     
         15 . The system of  claim 1 , wherein the nose is biased via a material characteristic of the nose. 
     
     
         16 . The system of  claim 15 , wherein the nose is fabricated from an elastomeric material. 
     
     
         17 . The system of  claim 1 , wherein an outer radial edge at an axial end surface of the nose is at least one of rounded and chamfered. 
     
     
         18 . The system of  claim 1 , wherein an inner radial edge at an axial end surface of the nose is at least one of rounded and chamfered. 
     
     
         19 . The system of  claim 18 , wherein an inner radial edge of the outlet at the distal end has a shape complimentary to the inner radial edge at the axial end surface of the nose. 
     
     
         20 . A system for additively manufacturing, comprising:
 an outlet through which a composite material is discharged; and   a nose that is a component separate from the outlet and located at a distal end of the outlet, wherein:
 a material forming the outlet is harder than a material forming the nose; and 
 the nose extends axially past the distal end of the outlet.