Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head configured to discharge a material, a first structure, and a second structure. The first structure may be configured to move the print head within a plane during discharge of the material. The second structure may be configured to move the print head within the plane during material discharge, the second structure being movable together with the print head by the first structure.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, a discharge head connected to and moveable by the support, a supply of reinforcement, and a rotary tensioner located between the supply and the discharge head. The rotary tensioner may be configured to impart tension to the reinforcement and to generate a signal indicative of the tension. The system may further include a drive associated with the supply, and a controller in communication with the rotary tensioner and the drive. The controller may be configured to selectively adjust a feed parameter of the drive based on the signal to maintain a desired level of tension.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet; a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface, and a cutting module located between the outlet and the compactor. The compactor and the cutting module may be configured to move together relative to the outlet.

Abstract: A print head is disclosed for use in additively manufacturing an object. The print head may have a housing, and a wetting module configured to wet a reinforcement with a liquid matrix. The print head may also include a matrix supply configured to hold a quantity of the liquid matrix and supply the liquid matrix to the wetting module.

Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first module configured to discharge a material, a second module configured to compact the material, and an actuator connected to the second module and configured to apply a force to the second module. The system may further include a controller in communication with the actuator. The controller may be configured to determine an operating parameter of the print head, and to selectively adjust the force applied by the actuator to the second module based on the operating parameter.

Abstract: A system is disclosed for use in additively manufacturing an object. The system may have a support and a first module operatively mounted to an end of the support and configured to discharge a material during motion of the support to form an object. The system may also have a second module configured to sever the material, at least a third module configured to at least one of compact or cure the material, and an actuator configured to cause movement of the second and the at least a third modules relative to the first module.

Abstract: A method is disclosed for us in additively manufacturing a three-dimensional carbon-bonded composite article. The method may include discharging from a print head a curable composition. The curable composition may include a) at least one aromatic, actinically curable component having an H/Catomic ratio of from 0.4 to 1.6, selected from the group consisting of (meth)acrylate oligomers, epoxy-functionalized compounds, oxetane-functionalized compounds and mixtures thereof; and b) at least one diluent comprising at least one actinically curable monomer. The curable composition may also include c) a reinforcement, and d) a photoinitiator. The method may further include irradiating the curable composition during the discharging to at least partially actinically cure the curable composition and form a preform of the three-dimensional carbon-bonded composite article. The method also includes pyrolyzing the preform to form the three-dimensional printed carbon-bonded composite article.

Abstract: A system is disclosed for additively manufacturing a structure. The system may have a support, and a print head operatively connected to and moveable by the support. The print head may include a first module configured to discharge a material, a second module configured to compact the material as it discharges from the first module, and a controller in communication with the second module. The controller may be configured to determine an as-discharged characteristic of the material, and to selectively adjust a force of the second module based on the as-discharged characteristic.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a continuous reinforcement, a second supply configured to hold a matrix separate from the continuous reinforcement, and a wetting mechanism in separate communication with the first and second supplies and configured to discharge the continuous reinforcement wetted with the matrix. The system may also include a controller programmed to selectively pressurize the second supply to direct the matrix to the wetting mechanism.

Abstract: A system is disclosed for use in additively manufacturing an object. The system may have a reinforcement supply, a matrix supply, and a wetting module configured to separately receive reinforcement from the reinforcement supply and matrix from the matrix supply and to discharge the reinforcement wetted with the matrix. The wetting module may include a body forming an enclosure and having an inlet end configured to receive the reinforcement and an outlet end configured to discharge the reinforcement wetted with the matrix. The wetting module may also include a plurality of nozzles dividing the enclosure into at least a wetting chamber.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.

Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.

Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a supply module configured to hold a reinforcement, and a wetting module. The wetting module may include a body with an inlet configured to separately receive the reinforcement and a matrix, and an outlet configured to discharge the reinforcement wetted with the matrix. The print head may also include a teasing mechanism disposed between the inlet and the outlet. The teasing mechanism may have multiple operating positions configured to affect varying levels of pressure against the reinforcement.

Abstract: A nozzle is disclosed for use in an additive manufacturing print head. The nozzle may include a body having a central passage with an entrant end and an exit end, and a shoulder protruding radially outward from the body at a location between the entrant and exit ends. A groove may be formed within an outer surface of the body at a location between the shoulder and the entrant end. The groove may be configured to receive a seal.

Abstract: A method is disclosed for additively manufacturing a structure. The method may include discharging from a print head a first layer of material inward of an outer boundary of the structure. The method may also include discharging from the print head a second layer of material adjacent the first layer and cantilevering past an edge of the first layer. The method may further include compacting a portion of the second layer of material cantilevered past the edge of the first layer to extend into and form a portion of the first layer of material.

Abstract: A system is disclosed for additively manufacturing an object. The system may include a first module configured to discharge a composite material including a continuous reinforcement and a matrix, and a cutting module located downstream of the first module and configured to sever the continuous reinforcement discharging from the first module. The cutting module may include a cutting mechanism configured to engage the continuous reinforcement, and a guide moveable to selectively abut the reinforcement during engagement of the reinforcement by the cutting mechanism.

Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material, a leading device, and a trailing device pivotally connected to the leading device. The leading device may be configured to engage and move over the material after discharge. The trailing device may be configured to engage and move over the material at a location trailing the leading device.

Abstract: A method is disclosed for additively manufacturing a composite structure. The method may include discharging a composite material from a print head and moving the print head during discharging to fabricate a preform from the composite material. The method may also include densifying the preform with a densifying material, and heating the preform to pyrolize the at least one of the composite material and the densifying material.

Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head configured to discharge a material, a first structure, and a second structure. The first structure may be configured to move the print head within a plane during discharge of the material. The second structure may be configured to move the print head within the plane during material discharge, the second structure being movable together with the print head by the first structure.