A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

A composite-material molding apparatus for molding a composite material, wherein the molding apparatus is provided with: a main body; a composite-material layer in which a molding face for molding a composite material is formed, the composite-material layer coating the surface of the main body; a filamentous fiber-optic temperature sensor embedded in the composite-material layer; a heating unit provided inside the main body; and a control device for controlling the heating unit on the basis of the temperature measured by the fiber-optic temperature sensor; the fiber-optic temperature sensor being disposed in planar fashion in a plane parallel to the molding face.

The invention relates to a method for continuous production of a composite material profile by injection-pultrusion from at least one reinforcing fabric and at least one thermoplastic polymer having high fluidity, said method being characterized in that: i) said fabric is continuously pulled with a pulling speed of at least 0.4 m.min.sup.−1 in the course of said process; ii) the impregnation stage is performed by injection of a polymeric composition having high fluidity through the fabric; iii) the profile is then shaped with a specific thermal profile.

The invention also relates to a profile obtained according to the method of the invention and a composite article comprising such a profile the curvature whereof may be modified in its curvature by bending and/or its profile by rotational molding.

The invention relates to a method for continuous production of a composite material profile by injection-pultrusion from at least one reinforcing fabric and at least one thermoplastic polymer having high fluidity, said method being characterized in that: i) said fabric is continuously pulled with a pulling speed of at least 0.4 m.min.sup.−1 in the course of said process; ii) the impregnation stage is performed by injection of a polymeric composition having high fluidity through the fabric; iii) the profile is then shaped with a specific thermal profile.

The invention also relates to a profile obtained according to the method of the invention and a composite article comprising such a profile the curvature whereof may be modified in its curvature by bending and/or its profile by rotational molding.

A method is disclosed for controlling an additive manufacturing system. The method may include causing a head to discharge composite material along a first trajectory, and activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory. The method may also include selectively deactivating the cure enhancer as the head nears a corner location, moving the head to a second trajectory after the head reaches the corner location, and reactivating the cure enhancer after moving the head to the second trajectory.

A method is disclosed for controlling an additive manufacturing system. The method may include causing a head to discharge composite material along a first trajectory, and activating a cure enhancer to at least partially cure composite material discharging from the head along the first trajectory. The method may also include selectively deactivating the cure enhancer as the head nears a corner location, moving the head to a second trajectory after the head reaches the corner location, and reactivating the cure enhancer after moving the head to the second trajectory.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

Co-curable and co-cured UV/visible light-resistant fiberglass-coated UV/visible light composite structural material substrates, and aircraft fuselages comprising co-cured UV/visible light-resistant fiberglass-coated composite material substrates and methods of their manufacture are disclosed.

Co-curable and co-cured UV/visible light-resistant fiberglass-coated UV/visible light composite structural material substrates, and aircraft fuselages comprising co-cured UV/visible light-resistant fiberglass-coated composite material substrates and methods of their manufacture are disclosed.