Additive manufacturing system implementing hardener pre-impregnation
A method is disclosed for additively manufacturing a composite structure. The method may include directing a continuous reinforcement into a print head, and coating the continuous reinforcement with a first matrix component inside of the print head. The method may further include coating the continuous reinforcement with a second matrix component, discharging the continuous reinforcement through a nozzle of the print head, and moving the print head in multiple dimensions during the discharging. The first and second matrix components interact to cause hardening of a matrix around the continuous reinforcement.
1. A prepreg material for use in manufacturing a composite structure, comprising:
a continuous reinforcement; and
a catalyst forming part of a multi-part matrix, which also includes at least a resin and that is curable around the continuous reinforcement to form the composite structure,
wherein:
the continuous reinforcement is at least partially saturated with the catalyst and free of the resin;
the continuous reinforcement makes up about 35-70% of the composite structure;
the catalyst makes up about 0.1-10% of the composite structure and is activated to cure the multi-part matrix only when a temperature of the multi-part matrix has been raised to an activation threshold temperature; and
a UV initiator in an amount sufficient to raise the multi-part matrix to the activation threshold temperature when exposed to a UV light during fabrication of the composite structure.
2. The prepreg material of claim 1 , wherein the resin is a thermoset polymer.
3. The prepreg material of claim 2 , wherein the thermoset polymer is one of an epoxy resin, a polyester resin, a vinylester resin.
4. The prepreg material of claim 1 , further including a spool around which the continuous reinforcement is wound.
5. The prepreg material of claim 1 , wherein the continuous reinforcement is an opaque fiber.
6. The prepreg material of claim 5 , wherein the opaque fiber is a carbon fiber.
7. A prepreg material for use in manufacturing a composite structure, comprising:
a continuous reinforcement;
a catalyst forming part of a multi-part matrix, which also includes at least a resin and that is curable around the continuous reinforcement to form the composite structure, and
a spool around which the continuous reinforcement is wound after at least partial saturation by the catalyst,
wherein:
the continuous reinforcement on the spool is free of the thermoset resin;
the continuous reinforcement makes up about 35-70% of the composite structure;
the catalyst makes up about 0.1-10% of the composite structure and is activated to cure the multi-part matrix only when a temperature of the multi-part matrix has been raised to an activation threshold temperature; and
a UV initiator in an amount sufficient to raise the multi-part matrix to the activation threshold temperature when exposed to a UV light during fabrication of the composite structure.
8. The prepreg material of claim 7 , wherein the thermoset resin is one of an epoxy resin, a polyester resin, a vinylester resin.
9. The prepreg material of claim 7 , wherein the continuous reinforcement is an opaque fiber.
10. The prepreg material of claim 9 , wherein the opaque fiber is a carbon fiber.
11. A prepreg material for use in manufacturing a composite structure, comprising:
a continuous reinforcement;
a catalyst forming part of a multi-part matrix, which also includes at least a resin and that is curable around the continuous reinforcement to form the composite structure, and
a UV initiator,
wherein:
the continuous reinforcement is at least partially saturated with the catalyst and free of the resin;
the continuous reinforcement makes up about 35-70% of the composite structure;
the catalyst makes up about 0.1-10% of the composite structure and is activated to cure the multi-part matrix only when a temperature of the multi-part matrix has been raised to an activation threshold temperature; and
the UV initiator is in an amount sufficient to raise the multi-part matrix to the activation threshold temperature when exposed to a UV light during fabrication of the composite structure.
12. The prepreg material of claim 11 , wherein the resin is a thermoset polymer.
13. The prepreg material of claim 12 , wherein the thermoset polymer is one of an epoxy resin, a polyester resin, a vinylester resin.
14. The prepreg material of claim 11 , further including a spool around which the continuous reinforcement is wound.