System, print head, and compactor for continuously manufacturing composite structure

1. A print head for an additive manufacturing system, comprising:

a matrix reservoir configured to hold a supply of matrix;

a nozzle connected to an end of the matrix reservoir;

a cure enhancer configured to expose a composite material being discharged from the nozzle to a cure energy; and

a compactor located between the nozzle and the cure enhancer and configured to compact the composite material prior to exposure to the cure energy, the compactor including:

a housing;

a compacting wheel; and

at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel; and

a sensor mounted at a leading side of the nozzle opposite the compactor and configured to generate a signal indicative of a surface condition of a structure being formed by the composite material.

2. The print head of claim 1 , further including an actuator configured to selectively adjust a distance between the housing and the compacting wheel.

3. The print head of claim 1 , further including a scraper mounted to the housing between the compacting wheel and the cure enhancer.

4. The print head of claim 2 , wherein the actuator is automatically actuated based on the signal.

5. The print head of claim 1 , wherein the surface condition includes at least one of a location, an orientation, a shape, a size, a material type, a hardness, an amount, and a type of support.

6. The print head of claim 1 , wherein the sensor is one of a lidar sensor, a radar sensor, a camera, a current sensor, an ultrasonic sensor, an infrared sensor, and a stereoscopic optical-type sensor.

7. A system for additively manufacturing a composite structure, comprising:

a nozzle configured to discharge a continuous reinforcement at least partially coated with a matrix;

a support configured to move the nozzle during discharging;

a compactor operatively connected to the nozzle and being adjustable to vary a compaction force exerted on the matrix-coated continuous reinforcement discharging from the nozzle;

a cure enhancer configured to expose the matrix to a cure energy;

a sensor mounted at a side of the nozzle opposite the compactor and configured to generate a signal indicative of a surface characteristic of the composite structure; and

a controller configured to selectively cause adjustment of the compactor based on the signal.

8. The system of claim 7 , wherein the surface condition includes at least one of a location, an orientation, a shape, a size, a material type, a hardness, an amount, and a type of support.

9. The system of claim 7 , wherein the sensor is one of a lidar sensor, a radar sensor, a camera, a current sensor, an ultrasonic sensor, an infrared sensor, and a stereoscopic optical-type sensor.

10. The system of claim 7 , wherein the compactor includes:

a compacting wheel;

a spring biasing the compacting wheel toward the matrix-coated continuous reinforcement;

an actuator selectively energized by the controller to affect a force of the spring.

11. A system for additively manufacturing a composite structure, comprising:

a print head configured to discharge a continuous reinforcement at least partially coated with a matrix;

a support configured to move the print head during discharging;

a compactor operatively connected to the print head and being adjustable to vary a compaction force exerted on the matrix-coated continuous reinforcement discharging from the print head;

a sensor mounted at a side of the print head opposite the compactor and configured to generate a signal indicative of a surface characteristic of the composite structure; and

a controller configured to selectively cause adjustment of the compactor based on the signal.

12. The system of claim 11 , further including a cure enhancer configured to expose the matrix to a cure energy.

13. The system of claim 12 , wherein the cure enhancer is configured to expose the matrix to the cure energy at a location trailing the compactor.

14. The system of claim 11 , further including a scraper mounted between the compactor and the cure enhancer.

15. The system of claim 11 , wherein:

the signal is indicative of an unsupported region of the composite structure; and

the controller is configured to responsively adjust the compactor to exert a lower compaction force.

16. The system of claim 11 , wherein:

the signal is indicative of a protruding region of the composite structure; and

the controller is configured to responsively adjust the compactor to exert a higher compaction force.

17. The system of claim 11 , wherein:

the signal is indicative of an excessive surface roughness of the composite structure; and

the controller is configured to responsively adjust the compactor to exert a higher compaction force.

18. The system of claim 6 , further including a scraper mounted between the compactor and the cure enhancer.