Additive manufacturing system and method for discharging coated continuous composites
A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to receive a continuous reinforcement, and at least one of a matrix jet and a matrix bath configured to wet the continuous reinforcement with a liquid matrix during passage through the print head. The system may also include a coating mechanism configured to dispense at least one of metallic and ceramic particles onto the wetted continuous reinforcement during passage through the print head, and at least one cure enhancer configured to at least one of cure the liquid matrix and cause the at least one of metallic and ceramic particles to coalesce around the continuous reinforcement. The system may further include a support configured to move the print head in multiple dimensions during discharging.
1. A method of additively manufacturing a composite structure, comprising:
directing into a print head a continuous reinforcement;
at least partially coating the continuous reinforcement with a liquid matrix inside the print head;
applying dry particles to an outer surface of the liquid matrix on the continuous reinforcement;
discharging from the print head a track containing the continuous reinforcement; and
exposing the track to energy to cause the particles to sinter.
2. The method of claim 1 , wherein exposing the track to energy includes exposing the track to energy as the track discharges from the print head.
3. The method of claim 2 , wherein exposing the track to energy includes causing the continuous reinforcement to melt away.
4. The method of claim 2 , wherein the continuous reinforcement remains intact after exposing the track to energy.
5. The method of claim 1 , further including exposing the liquid matrix on the continuous reinforcement to energy to cause the liquid matrix to cure, prior to exposing the track to energy to cause the particles to sinter.
6. The method of claim 5 , wherein:
exposing the track to energy includes exposing the track to at least one of infrared heat and laser energy; and
exposing the liquid matrix on the continuous reinforcement to energy includes exposing the liquid matrix to UV light.
7. The method of claim 1 , wherein exposing the track to energy includes exposing all tracks making up the composite structure to energy at the same time, after the composite structure is formed.
8. The method of claim 1 , further including moving the print head in multiple dimensions during discharging of the track.
9. A method of additively manufacturing a composite structure, comprising:
directing into a print head a continuous reinforcement;
at least partially coating the continuous reinforcement with a liquid matrix inside the print head;
applying at least one of metallic particles and ceramic particles to the liquid matrix on the continuous reinforcement;
discharging from the print head a track containing the continuous reinforcement; and
exposing the track to energy to cause the at least one of metallic particles and ceramic particles to sinter,
wherein applying at least one of metallic particles and ceramic particles to the liquid matrix on the continuous reinforcement includes spraying the at least one of metallic particles and ceramic particles onto the liquid matrix prior to discharge of the continuous reinforcement from the print head.
10. The method of claim 9 , wherein at least partially coating the continuous reinforcement with the liquid matrix includes at least one of spraying the continuous reinforcement with the liquid matrix and passing the continuous reinforcement through a bath of the liquid matrix.
11. The method of claim 10 , wherein the liquid matrix is a flux configured to facilitate coalescence of the at least one of metallic particles and ceramic particles.
12. A method of additively manufacturing a composite structure, comprising:
discharging a continuous reinforcement that is wetted with a liquid matrix from a print head;
moving the print head during discharging to shape the composite structure;
exposing the liquid matrix to energy from a first energy source to harden the liquid matrix and maintain the shape of the composite structure;
applying particles to the wetted continuous reinforcement; and
exposing the particles to energy from a second energy source to sinter the particles after the liquid matrix has hardened.
13. The method of claim 12 , further including wetting the continuous reinforcement with the liquid matrix prior to applying the particles.
14. The method of claim 13 , wherein the liquid matrix is a flux configured to facilitate coalescence of the particles.
15. The method of claim 12 , wherein sintering the particles causing the continuous reinforcement to melt away.
16. The method of claim 12 , wherein the continuous reinforcement remains intact after sintering of the particles.
17. The method of claim 12 , wherein the particles include at least one of metallic particles and ceramic particles.
18. The method of claim 12 , wherein applying particles to the liquid matrix on the continuous reinforcement includes applying the particles prior to discharge of the continuous reinforcement from the print head.
19. The method of claim 12 , wherein the continuous reinforcement includes at least one of a fiber and a wire.