ADDITIVE MANUFACTURING SYSTEM HAVING IN-SITU REINFORCEMENT FABRICATION
A system for additively manufacturing a composite part is disclosed. The system may include a support moveable in multiple dimensions, and a print head connected to an end of the support. The print head may have a first matrix reservoir configured to wet a continuous strand reinforcement, a first nozzle fluidly connected to the first matrix reservoir, and a first cure enhancer located to expose the continuous strand reinforcement to cure energy upon discharge from the nozzle. The system may also include an in-situ fiber-making apparatus configured to supply the continuous strand reinforcement to the matrix reservoir of the print head.
1 . An additive manufacturing system, comprising:
a support moveable in multiple dimensions;
a print head connected to an end of the support and including:
a first matrix reservoir configured to wet a continuous strand reinforcement;
a first nozzle fluidly connected to the first matrix reservoir; and
a first cure enhancer located to expose the continuous strand reinforcement to cure energy upon discharge from the first nozzle; and
an in-situ fiber-making apparatus configured to supply the continuous strand reinforcement to the first matrix reservoir of the print head.
2 . The additive manufacturing system of claim 1 , wherein the in-situ fiber-making apparatus includes:
a second matrix reservoir;
at least a second nozzle fluidly connected to the second matrix reservoir; and
a second cure enhancer located to cure matrix material discharging from the at least a second nozzle into continuous strand reinforcement.
3 . The additive manufacturing system of claim 2 , wherein the in-situ fiber-making apparatus is mechanically and fluidly connected to the print head.
4 . The additive manufacturing system of claim 2 , wherein the at least a second nozzle includes a plurality of nozzles configured to discharge a plurality of continuous strand reinforcements.
5 . The additive manufacturing system of claim 4 , wherein the plurality of nozzles is arranged in a circle around a central opening.
6 . The additive manufacturing system of claim 5 , further including a supply configured to direct a pre-fabricated continuous strand reinforcement through the central opening.
7 . The additive manufacturing system of claim 6 , wherein the pre-fabricated continuous strand reinforcement includes at least one of a resister, a capacitor, a light-emitting diode, an RFID tag, a switch, a battery, a fuse, and a filter integrated between connected fiber strands.
8 . The additive manufacturing system of claim 4 , further including at least one actuator configured to move the plurality of nozzles and weave the plurality of continuous strand reinforcements.
9 . The additive manufacturing system of claim 1 , wherein the in-situ fiber-making apparatus includes:
a hopper;
a die through which material from the hopper is pressed to form the continuous strand reinforcement; and
a heater configured to liquefy the material from the hopper.
10 . The additive manufacturing system of claim 1 , further including:
a hopper; and
a die through which material from the hopper is pressed to form a pre-fabricated continuous strand material that is directed through the print head along with the continuous strand reinforcement from the in-situ fiber-making apparatus.
11 . The additive manufacturing system of claim 1 , further including a first mobile undercarriage on which the support is mounted.
12 . The additive manufacturing system of claim 11 , further including a second mobile undercarriage towed by the first mobile undercarriage and configured to support the in-situ fiber-making apparatus.
13 . A method of additively manufacturing a composite structure, comprising:
fabricating a continuous strand reinforcement;
wetting the continuous strand reinforcement with a matrix, as the continuous strand reinforcement is fabricated;
discharging the matrix-wetted continuous strand reinforcement through a nozzle; and
exposing the matrix wetting the continuous strand reinforcement to cure energy upon discharge from the nozzle; and
moving the nozzle in multiple dimensions during discharge.
14 . The method of claim 13 , wherein fabricating the continuous strand reinforcement includes:
directing a second matrix through at least a second nozzle to form the continuous strand reinforcement; and
hardening the continuous strand reinforcement before wetting the continuous strand reinforcement.
15 . The method of claim 14 , wherein directing the second matrix through the at least a second nozzle includes directing the second matrix through a plurality of nozzles to form a plurality of continuous strand reinforcements.
16 . The method of claim 15 , further including directing a pre-fabricated continuous strand reinforcement through a central opening between the plurality of nozzles.
17 . The method of claim 15 , further including weaving the plurality of continuous strand reinforcements.
18 . The method of claim 13 , wherein fabricating the continuous strand reinforcement includes pressing raw material from a hopper through a die.
19 . The method of claim 18 , further including liquefying the raw material from the hopper prior to pressing the raw material through the die.
20 . The method of claim 13 , wherein:
moving the nozzle in multiple dimensions during discharge includes moving a print head housing the nozzle with a support; and
the method further includes:
mobilizing the support; and
at least one of carrying on the support and towing behind the support an apparatus fabricating the continuous strand reinforcement.