System and method for additively manufacturing a composite structure
A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.
1. A method of additively manufacturing a composite structure, comprising:
discharging from a print head a matrix-coated continuous reinforcement onto a build surface;
submerging the matrix-coated continuous reinforcement in resin;
exposing resin at a surface of the matrix-coated continuous reinforcement to a cure energy; and
exposing a matrix in the matrix-coated continuous reinforcement to cure energy to at least partially cure the matrix prior to submerging the matrix-coated continuous reinforcement in resin.
2. The method of claim 1 , further including incrementally lowering the matrix-coated continuous reinforcement into the resin.
3. The method of claim 2 , further including passing resin through the build surface during incremental lowering of the matrix-coated continuous reinforcement.
4. The method of claim 2 , further including incrementally raising a level of resin inside a vat housing the build surface.
5. The method of claim 4 , further including moving the print head inside the vat.
6. The method of claim 1 , further including interleaving cured layers of the matrix-coated continuous reinforcement with cured layers of the resin.
7. A method of additively manufacturing a composite structure, comprising:
discharging from a print head a matrix-coated continuous reinforcement onto a build surface;
submerging the matrix-coated continuous reinforcement in resin;
exposing resin at a surface of the matrix-coated continuous reinforcement to a cure energy; and
at least partially curing all of the matrix-coated continuous reinforcement prior to curing of any resin on the surface of the matrix-coated continuous reinforcement.
8. The method of claim 1 , wherein exposing resin at the surface of the matrix-coated continuous reinforcement to the cure energy includes directing the cure energy through the build surface.
9. The method of claim 1 , further including generating an oxygen inhibiting barrier at a surface of the resin.
10. A method of additively manufacturing a composite structure, comprising:
discharging from a matrix-coated continuous reinforcement onto a build surface;
at least partially submerging the matrix-coated continuous reinforcement in resin;
curing the resin; and
exposing a matrix in the matrix-coated continuous reinforcement to cure energy to at least partially cure the matrix prior to at least partially submerging the matrix-coated continuous reinforcement in resin.
11. The method of claim 10 , wherein exposing the matrix to cure energy includes directing light into the matrix.
12. The method of claim 10 , further including incrementally lowering the matrix-coated continuous reinforcement into the resin.
13. The method of claim 12 , further including passing resin over the build surface during incremental lowering of the matrix-coated continuous reinforcement.
14. The method of claim 10 , further including incrementally raising a level of resin inside a vat housing the build surface.
15. The method of claim 10 , further including interleaving cured layers of the matrix-coated continuous reinforcement with cured layers of the resin.
16. A method of additively manufacturing a composite structure, comprising:
discharging from a matrix-coated continuous reinforcement onto a build surface;
at least partially submerging the matrix-coated continuous reinforcement in resin;
curing the resin; and
at least partially curing all of the matrix-coated continuous reinforcement prior to curing of any resin.
17. The method of claim 10 , wherein curing resin includes directing cure energy through the build surface.
18. The method of claim 17 , wherein the cure energy is UV light.
19. The method of claim 10 , further including generating an oxygen inhibiting barrier at a surface of the resin.