System and print head for continuously manufacturing composite structure

Abstract

A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement at least partially coated with a matrix. The head may have a matrix reservoir, and a nozzle connected to an end of the matrix reservoir. The system may further include a support configured to move the head during discharging, and a supply of matrix. The system may also include at least one sensor configured to generate a signal indicative of a matrix characteristic inside of the head, and a controller configured to selectively affect the supply of matrix based on the signal.

What is claimed is: 
     
         1 . A method of additively manufacturing a structure, comprising:
 discharging a matrix from a reservoir inside of a print head;   moving the print head during discharging to form the structure from the matrix;   sensing an amount of the matrix in the reservoir; and   selectively pumping additional matrix from a supply remote from the reservoir into the reservoir based on the amount.   
     
     
         2 . The method of  claim 1 , further including coating a continuous reinforcement with the matrix prior to discharging the matrix. 
     
     
         3 . The method of  claim 1 , further including selectively activating a valve disposed between the supply and the print head based on the amount. 
     
     
         4 . The method of  claim 1 , further including directing energy at the matrix to harden the matrix. 
     
     
         5 . A method of additively manufacturing a structure, comprising:
 discharging a matrix from a print head;   moving the print head during discharging to form the structure from the matrix;   sensing a characteristic of the matrix inside the print head; and   selectively affecting a supply of matrix from a remote location into the print head based on the characteristic.   
     
     
         6 . The method of  claim 5 , wherein the characteristic is a pressure. 
     
     
         7 . The method of  claim 5 , wherein the characteristic is a temperature. 
     
     
         8 . The method of  claim 5 , wherein the characteristic is a volume. 
     
     
         9 . The method of  claim 5 , wherein selectively affecting the supply includes affecting a flow rate. 
     
     
         10 . The method of  claim 5 , wherein selectively affecting the supply includes affecting a pressure. 
     
     
         11 . The method of  claim 5 , wherein selectively affecting the supply includes affecting a temperature. 
     
     
         12 . The method of  claim 5 , wherein selective affecting the supply includes increasing an output of a matrix pump. 
     
     
         13 . The method of  claim 12 , wherein the output includes at least one of a flowrate and a pressure. 
     
     
         14 . An additive manufacturing system, comprising:
 a print head having an outlet and a matrix supply located away from the outlet;   a support configured to move the print head during discharging of matrix from the outlet of the print head;   a sensor configured to generate a signal indicative of a characteristic of the matrix at the outlet; and   a controller configured to selectively affect the matrix supply based on the signal.   
     
     
         15 . The additive manufacturing system of  claim 14 , wherein the matrix supply includes a pump. 
     
     
         16 . The additive manufacturing system of  claim 14 , wherein the outlet is part of a nozzle of the print head. 
     
     
         17 . The additive manufacturing system of  claim 16 , wherein the print head includes a reservoir located upstream of the outlet, and the sensor is associated with the reservoir. 
     
     
         18 . The additive manufacturing system of  claim 17 , wherein the matrix supply includes a pump in fluid communication with the reservoir. 
     
     
         19 . The additive manufacturing system of  claim 18 , wherein the controller is configured to selectively affect an output of the pump based on the signal. 
     
     
         20 . The additive manufacturing system of  claim 19 , wherein the characteristic is a pressure.