A method (400) of additively manufacturing a composite part (102) comprises applying a liquid photopolymer resin (252) to a non-resin component (108) to create a continuous flexible line (106) by pulling the non-resin component (108) through a vessel (236), containing a volume of the liquid photopolymer resin (252). The continuous flexible line (106) comprises the non-resin component (108) and a photopolymer-resin component (110) that comprises at least some of the liquid photopolymer resin (252) applied to the non-resin component (108). The method (400) further comprises routing the continuous flexible line (106) into a delivery guide (112), pushing the continuous flexible line (106) out of the delivery guide (112), depositing, via the delivery guide (112), a segment (120) of the continuous flexible line (106) along a print path (122), and delivering curing energy (118) at least to a portion (124) of the segment (120) of the continuous flexible line (106).

A method (300) of additively manufacturing a composite part (102) is disclosed. The method (300) comprises pushing a continuous flexible line (106) through a delivery guide (112). The continuous flexible line (106) comprises a non-resin component (108) and a thermosetting-epoxy-resin component (110) that is partially cured. The method (300) also comprises depositing, via the delivery guide (112), a segment (120) of the continuous flexible line (106) along a print path (122). The method (300) further comprises maintaining the thermosetting-epoxy-resin component (110) of at least the continuous flexible line (106) being pushed through the delivery guide (112) below a threshold temperature prior to depositing the segment (120) of the continuous flexible line (106) along the print path (120).

A method (300) of additively manufacturing a composite part (102) is disclosed. The method (300) comprises depositing a segment (120) of a continuous flexible line (106) along a print path (122). The continuous flexible line (106) comprises a non-resin component (108) and a thermosetting resin component (110) that is not fully cured. The method (300) further comprises, while advancing the continuous flexible line (106) toward the print path (122), delivering a predetermined or actively determined amount of curing energy (118) at least to a portion (124) of the segment (120) of the continuous flexible line (106) at a controlled rate after the segment (120) of the continuous flexible line (106) is deposited along the print path (122) to at least partially cure at least the portion (124) of the segment (120) of the continuous flexible line (106).

A method (500) of additively manufacturing a composite part (102) comprises applying a first quantity of a first part (253) of a thermosetting resin (252) to a first element (271) of a non-resin component (108) by pulling the first element (271) through a first resin-part applicator (236) and applying a second quantity of a second part (255) of the thermosetting resin (252) to a second element (273) of the non-resin component (108) by pulling the second element (273) through a second resin-part applicator (237). The method (500) also comprises combining the first element (271) with the first quantity of first part (253) and the second element (273) with the second quantity of second part (255), to create a continuous flexible line (106). The method (500) additionally comprises routing the continuous flexible line (106) into a delivery guide (112) and depositing, via the delivery guide (112), a segment (120) of the continuous flexible line (106) along a print path (122).

A system (100) for additively manufacturing a composite part (102) is disclosed. The system (100) comprises a housing (104) and a nozzle (107). The nozzle (107) is supported by the housing (104). The nozzle (107) comprises an outlet (110), sized to dispense a continuous flexible line (112). The continuous flexible line (112) comprises a non-resin component (114) and a photopolymer-resin component (116). The system (100) also comprises a feed mechanism (118), supported within the housing (104). The feed mechanism (118) is configured to push the continuous flexible line (112) out of the outlet (110) of the nozzle (107). The system (100) further comprises a light source (120), supported by the housing (104). The light source (120) is configured to deliver a light beam to the continuous flexible line (112) after the continuous flexible line (112) exits the outlet (110) of the nozzle (107) to at least partially cure the photopolymer-resin component (116) of the continuous flexible line (112).

A system (700) for additively manufacturing a composite part (102) comprises a delivery guide (112), movable relative to a surface (114). The delivery guide (112) is configured to deposit at least a segment (120) of a continuous flexible line (106) along a print path (122). The continuous flexible line (106) comprises a non-resin component (108) and a thermosetting-resin component (110). The thermosetting-resin component (110) comprises a first part (253) and a second part (255). The non-resin component (108) comprises a first element (271) and a second element (273). The system (700) further comprises a first resin-part applicator (236), configured to apply the first part (253) to the first element (271), and a second resin-part applicator (237), configured to apply the second part (255) to the second element (273). The system (700) also comprises a feed mechanism (104), configured to pull the first element (271) through the first resin-part applicator (236), to pull the second element (273) through the second resin-part applicator (237), and to push the continuous flexible line (106) out of the delivery guide (112).

A system (700) for additively manufacturing a composite part (102) comprises a delivery guide (112), movable relative to a surface (114). The delivery guide (112) is configured to deposit at least a segment (120) of a continuous flexible line (106) along a print path (122). The continuous flexible line (106) comprises a non-resin component (108) and a thermosetting-resin component (110). The thermosetting-resin component (110) comprises a first part (253) and a second part (255). The non-resin component (108) comprises a first element (271) and a second element (273). The system (700) further comprises a first resin-part applicator (236), configured to apply the first part (253) to the first element (271), and a second resin-part applicator (237), configured to apply the second part (255) to the second element (273). The system (700) also comprises a feed mechanism (104), configured to pull the first element (271) through the first resin-part applicator (236), to pull the second element (273) through the second resin-part applicator (237), and to push the continuous flexible line (106) out of the delivery guide (112).

A manufacturing method for a component made from composite material, in particular of a turbomachine, includes the steps of producing a preform with a fibrous reinforcement comprising a first fibrous portion and a second fibrous portion, and injecting a pressurized matrix into an injection chamber of an injection mold, in which the preform is arranged. The method further includes the steps of polymerizing the preform and positioning a flexible pocket that encloses a fluid and that is arranged between the first fibrous portion and the second fibrous portion before the injection step. The fluid is configured to apply an additional pressure to the preform of the fluid during the polymerization step.

A manufacturing method for a component made from composite material, in particular of a turbomachine, includes the steps of producing a preform with a fibrous reinforcement comprising a first fibrous portion and a second fibrous portion, and injecting a pressurized matrix into an injection chamber of an injection mold, in which the preform is arranged. The method further includes the steps of polymerizing the preform and positioning a flexible pocket that encloses a fluid and that is arranged between the first fibrous portion and the second fibrous portion before the injection step. The fluid is configured to apply an additional pressure to the preform of the fluid during the polymerization step.

A composite filament melt impregnation device with an automatic lifting channel for additive manufacturing includes a mechanical lifting device, a heating device, a curved resin impregnation channel, a filament guide block, a single screw extruder, a replaceable combination die nozzle, and a resin riser. The composite filament melt impregnation device can significantly improve the efficiency of replacing filaments and treating broken filaments in a forming process of continuous fiber filaments, reduce the operation difficulty of a production process, and ensure the safety of operators. The design of the resin riser can achieve slight dynamic adjustment of pressure in a melt cavity in the production process, improve the stability of product quality, and ultimately achieve continuous production and rapid replacement of high-performance continuous fiber composites.