System and head for continuously manufacturing composite structure

Abstract

A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to discharge a continuous reinforcement that is at least partially coated in a matrix, and a compactor configured to compact the continuous reinforcement and the matrix. The system may also include a cure enhancer configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor.

What is claimed is: 
     
         1 . An additive manufacturing system, comprising:
 a support; and   a print head operatively connected to and moveable in a travel direction by the support, the print head including:
 an outlet configured to discharge a material during motion in the travel direction, the material trailing from the outlet in a direction opposite the travel direction; 
 a compactor configured to compact the material during discharge; and 
 a cure enhancer leading the outlet relative to the travel direction and configured to direct cure energy toward the material being discharged. 
   
     
     
         2 . The additive manufacturing system of  claim 1 , wherein the cure enhancer is configured to expose the material to cure energy prior to the material being compacted by the compactor. 
     
     
         3 . The additive manufacturing system of  claim 2 , wherein:
 the cure enhancer is a first cure enhancer; and   the additive manufacturing system further includes a second cure enhancer configured to direct cure energy toward the material in at least one of a different direction or at a different location.   
     
     
         4 . The additive manufacturing system of  claim 3 , wherein the second cure enhancer trails the outlet relative to the travel direction. 
     
     
         5 . The additive manufacturing system of  claim 4 , wherein the second cure enhancer also trails the compactor. 
     
     
         6 . The additive manufacturing system of  claim 3 , wherein the second cure enhancer leads the outlet. 
     
     
         7 . The additive manufacturing system of  claim 3 , wherein the second cure enhancer is configured to expose the material to cure energy after the material has been compacted by the compactor. 
     
     
         8 . The additive manufacturing system of  claim 3 , wherein the second cure enhancer is configured to expose the material to cure energy at a same location where the material is being compacted by the compactor. 
     
     
         9 . The additive manufacturing system of  claim 3 , wherein:
 the first cure enhancer is configured to expose the material to cure energy from a direction that is orthogonal to an axis of the compactor; and   the second cure enhancer is configured to expose the material to cure energy from an angle that is one of parallel or oblique to the axis of the compactor.   
     
     
         10 . The additive manufacturing system of  claim 1 , wherein a portion of the compactor is configured to block cure energy from the cure enhancer. 
     
     
         11 . The additive manufacturing system of  claim 10 , wherein the portion of the compactor is located at a side oriented toward the cure enhancer. 
     
     
         12 . The additive manufacturing system of  claim 1 , wherein the cure energy passes from a leading outside of the compactor, through the compactor, to the material being compacted. 
     
     
         13 . The additive manufacturing system of  claim 1 , wherein the compactor includes a wheel, and an annular groove in the wheel that is configured to guide the material. 
     
     
         14 . The additive manufacturing system of  claim 1 , wherein the compactor is configured to redirect a path of cure energy. 
     
     
         15 . An additive manufacturing system, comprising:
 a support; and   a print head operatively connected to and moveable in a travel direction by the support, the print head including:
 an outlet configured to discharge a material during motion in the travel direction, the material trailing from the outlet in a direction opposite the travel direction; 
 a compactor having a wheel configured to compact the material during discharge; 
 a first cure enhancer configured to direct cure energy toward the material being discharged from a direction that is orthogonal to an axis of the wheel; and 
   a second cure enhancer configured to direct cure energy toward the material being discharged from a direction that is one of parallel or oblique to the axis of the wheel.   
     
     
         16 . The additive manufacturing system of  claim 15 , wherein at least one of the first or second cure enhancers is configured to expose the material to cure energy prior to the material being compacted by the compactor. 
     
     
         17 . The additive manufacturing system of  claim 15 , wherein at least one of first or second cure enhancers trails the outlet relative to the travel direction. 
     
     
         18 . The additive manufacturing system of  claim 17 , wherein at least one of first or second cure enhancers also trails the compactor. 
     
     
         19 . The additive manufacturing system of  claim 15 , wherein both of the first and second cure enhancers leads the outlet. 
     
     
         20 . The additive manufacturing system of  claim 15 , wherein at least one of the first or second cure enhancers is configured to expose the material to cure energy at a same location where the material is being compacted by the compactor.