Additive manufacturing system having multi-channel nozzle
A system is disclosed for use in additively manufacturing a composite structure. The system may include a matrix reservoir, and a fiber guide configured to separately receive a plurality of matrix-wetted reinforcements from the matrix reservoir. The system may also include a die configured to receive the plurality of matrix-wetted reinforcements from the fiber guide and to cause the plurality of matrix-wetted reinforcements to converge into a ribbon. The system may additionally include a cure enhancer configured to cure the matrix in the composite material during discharge of the ribbon from the die, and a support configured to move the die in multiple dimensions during discharge of the ribbon.
1. A nozzle for a head of an additive manufacturing system, comprising:
a housing;
a fiber guide configured to receive a plurality of continuous reinforcements, the fiber guide being located inside the housing and including a plurality of channels that extend along a length of the housing and the plurality of continuous reinforcements and separate the plurality of continuous reinforcements from each other; and
a die located inside the housing at outlets of the plurality of channels, the die having a cross-sectional area less than a combined cross-sectional area of the plurality of channels to receive the plurality of continuous reinforcements from the fiber guide and to cause the plurality of continuous reinforcements to converge into a ribbon, wherein
the fiber guide includes a plurality of protrusions that separate the plurality of channels.
2. The nozzle of claim 1 , wherein the cover housing includes an integral protrusion having a tapered upstream end and a downstream end that extends transversely toward the plurality of protrusions.
3. The nozzle of claim 1 , wherein the die includes a reduced number of channels compared to the fiber guide.
4. The nozzle of claim 1 , wherein the die has a rounded trailing edge at an end opposite the fiber guide.
5. The nozzle of claim 1 , wherein at least one of the fiber guide and the die includes an internal coating of a reduced friction material.
6. A head for an additive manufacturing system, comprising:
a matrix reservoir;
a fiber guide configured to receive a plurality of matrix-wetted reinforcements from the matrix reservoir, the fiber guide including a plurality of channels that extend along a length of the plurality of matrix-wetted reinforcements and separate the plurality of matrix-wetted reinforcements from each other; and
a die configured to receive the plurality of matrix-wetted reinforcements from the fiber guide and to cause the plurality of matrix-wetted reinforcements to converge.
7. The head of claim 6 , further including a cure enhancer configured to expose the plurality of matrix-wetted reinforcements discharging from the die to energy and increase a rate of chemical reaction occurring within the plurality of matrix-wetted reinforcements.
8. The head of claim 6 , wherein:
the fiber guide includes a plurality of protrusions that separate the plurality of axially oriented channels; and
the head includes a nozzle housing having:
a base that is integral with the plurality of protrusions; and
a cover that is removable from the base to provide access to the plurality of axially oriented channels.
9. The head of claim 8 , wherein the cover includes an integral protrusion having a tapered upstream end and a downstream end that extends transversely toward the plurality of protrusions.
10. The head of claim 6 , wherein the die includes a reduced number of channels compared to the fiber guide.
11. The head of claim 6 , wherein the die has a rounded trailing edge.
12. The head of claim 6 , wherein at least one of the fiber guide and the die includes an internal coating of a reduced friction material.
13. An additive manufacturing system, comprising:
a matrix reservoir;
a fiber guide configured to receive a plurality of matrix-wetted reinforcements from the matrix reservoir and maintain a separation between the plurality of matrix-wetted reinforcements;
a die configured to receive the plurality of matrix-wetted reinforcements from the fiber guide and to cause the plurality of matrix-wetted reinforcements to converge into a ribbon;
a cure enhancer configured to cure matrix in the ribbon during discharge of the ribbon from the die; and
a support configured to move the die in multiple dimensions during discharge of the ribbon.
14. The additive manufacturing system of claim 13 , wherein the fiber guide includes a plurality of channels that extend along a length of the plurality of matrix-wetted reinforcements and are separated by a plurality of protrusions.
15. The additive manufacturing system of claim 14 , further including a housing configured to house at least the fiber guide, the housing having:
a base that is integral with the plurality of protrusions; and
a cover that is removable from the base to provide access to the plurality of axially oriented channels.
16. The additive manufacturing system of claim 15 , wherein the cover includes an integral protrusion that extends transversely toward the plurality of protrusions to reduce a cross-sectional area of the die.
17. The additive manufacturing system of claim 13 , wherein the die includes:
a reduced number of channels compared to the fiber guide; and
a rounded trailing edge at an end opposite the fiber guide.