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 (100) for additively manufacturing a composite part (102) is disclosed. The system (100) 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) that comprises a first part (253) and a second part (255) of a thermosetting resin (252). The print path (122) is stationary relative to the surface (114). The delivery guide (112) comprises a first inlet (170) configured to receive the non-resin component (108), and a second inlet (250) configured to receive at least the first part (253) of the thermosetting resin (252). The delivery guide (112) is further configured to apply the first part (253) and the second part (255) of the thermosetting resin (252) to the non-resin component (108). The system 100 further comprises a feed mechanism (104), configured 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 moldable composite with high heat resistance and noise absorption properties utilizes nonwoven fabrics and a heat resistance additive. The composition that provides both superior acoustic performance and excellent flex modulus that may be utilized in automotive products and applications in interior and exterior structures. A blowing agent may be utilized to create micro porous cells in a polymer non-woven structure. The cells or voids make the material lighter and allow the material to have superior acoustic properties that are useful in automotive applications.

A packing material including a plurality of discrete cushioning elements and methods for making the same. The discrete cushioning elements may be cellulosic cushioning elements. A flexible linkage may connect the plurality of discrete cushioning elements in the packing material. The packing material may also include a bottom cellulosic sheet connected to a top cellulosic sheet with the plurality of cellulosic cushioning elements positioned between the top cellulosic sheet and the bottom cellulosic sheet. The packing material may also be a molded packing material that includes bonds comprising adhesive and cellulosic fibers. The adhesive and cellulosic fibers of the bonds may be dispersed between the folds of each of the cellulosic cushioning elements.

A method for manufacturing acoustical elements, includes providing a first fibre component in a form of mineral wool and a second fibre component in a form of bicomponent fibres having a core with a thermoplastic outer layer, mixing the first fibre component and the second fibre component, for provision of a mixture, shaping the mixture into single layered tile shaped elements whereby the mixture is compressed with a compression ratio to a compressed state, and fixating the single layered tile shaped elements in the compressed state for obtaining the acoustical elements.