The application describes methods of making composite bodies including fibre-reinforced composite material with carbon fibre reinforcement and also a metal-containing portion (4). The metal-containing portion (4) is formed by laying up metal reinforcement elements, such as tapes of titanium alloy, among the carbon fibre reinforcement tapes which make up the composite body. The proportion of metal reinforcement may increase progressively towards the surface and/or towards an edge (14) of the composite body. In an example, metal leading and trailing edges (14,15) of a fan blade (1) are integrally formed in this way.

A method and apparatus for resistive heating usable in composite-based additive manufacturing is disclosed. The method includes providing a prepared stack of substrate sheets, placing the stack between electrode assemblies of a compression device, applying a current to thereby heat the stack to a final temperature to liquefy applied powder, compressing the stack to a final height, cooling the stack, and removing the cooled, compressed stack from the compression device. The apparatus comprises at least two plates, a power supply for providing current, a first electrode assembly and a second electrode assembly.

A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a compactor located at the discharging end and forming a tool center point for the print head.

A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a feeder located between the receiving end and the discharging end. The feeder may be configured to push the continuous reinforcement out of the print head at only select times during discharge of the continuous reinforcement and the matrix.

A print head is disclosed for use in an additive manufacturing system. The print head may include a first end configured to receive a continuous reinforcement, and a second end configure to discharge the continuous reinforcement at least partially coated in a matrix. The print head may also include a cutting module disposed between the first and second ends. The cutting module may include a blade, an anvil, and an actuator operatively connected to at least one of the blade and the anvil.

A method is provided for fabricating a carbon nanotube metal matrix composite. The method may include forming a molten mixture by combining carbon nanotubes with a molten solution. The carbon nanotubes combined with the molten solution may be dispersed therein. The method may also include transferring the molten mixture to a mold and applying a magnetic field to the molten mixture in the mold to substantially align at least a portion of the carbon nanotubes with one another. The method may further include solidifying the molten mixture in the mold to fabricate the carbon nanotube metal matrix composite, where at least a portion of the carbon nanotubes may be substantially aligned in the carbon nanotube metal matrix composite.

A method is provided for fabricating a carbon nanotube metal matrix composite. The method may include forming a molten mixture by combining carbon nanotubes with a molten solution. The carbon nanotubes combined with the molten solution may be dispersed therein. The method may also include transferring the molten mixture to a mold and applying a magnetic field to the molten mixture in the mold to substantially align at least a portion of the carbon nanotubes with one another. The method may further include solidifying the molten mixture in the mold to fabricate the carbon nanotube metal matrix composite, where at least a portion of the carbon nanotubes may be substantially aligned in the carbon nanotube metal matrix composite.

The embodiments relate to a method for additive manufacturing of a component made from a metal matrix composite for a vehicle. In a step of the method, a plurality of elongated filaments is provided. In another step, metallic powder is provided. In a further step, the metal matrix composite component is additively manufactured by melting the metallic powder.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

A method includes fabricating a part out of composite material including fiber reinforcement densified by a metal matrix.