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 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 method for producing a prepreg, includes the steps of (1) an opening step of opening glass fiber bundles to form plural glass fiber filaments, and (2) a step of aligning the plural glass fiber filaments formed in the previous opening step, on a thermosetting resin composition-coated surface of a carrier material so as to make the filaments run nearly parallel to each other in one direction thereon to form a prepreg. A method for producing a laminate, includes a step of preparing two or more prepregs formed in the previous step (2), laminating them in such a manner that, in at least one pair of prepregs, the running direction of the plural glass fiber filaments in one prepreg differs from the running direction of the plural glass fiber filaments in the other prepreg, and heating and pressing them.

A method for producing a prepreg, includes the steps of (1) an opening step of opening glass fiber bundles to form plural glass fiber filaments, and (2) a step of aligning the plural glass fiber filaments formed in the previous opening step, on a thermosetting resin composition-coated surface of a carrier material so as to make the filaments run nearly parallel to each other in one direction thereon to form a prepreg. A method for producing a laminate, includes a step of preparing two or more prepregs formed in the previous step (2), laminating them in such a manner that, in at least one pair of prepregs, the running direction of the plural glass fiber filaments in one prepreg differs from the running direction of the plural glass fiber filaments in the other prepreg, and heating and pressing them.

A fiber-reinforced resin composite material has a longitudinal direction, and includes a first stack, a second stack, a ridge, a flat surface, and a connection. The ridge extends in the longitudinal direction. The flat surface is continuous to the ridge. The connection is where the first and second stacks are coupled. The first and second stacks are joined to each other in a direction intersecting the longitudinal direction. Fibers of at least one of first fiber-reinforced resin sheets included in the first stack, fibers of at least one of second fiber-reinforced resin sheets included in the second stack, or both intersect the ridge. The connection includes the first and second fiber-reinforced resin sheets that are overlapped alternately, and includes ends of the first fiber-reinforced resin sheets, ends of the second fiber-reinforced resin sheets, or both that are shifted from each other to allow the connection to have a gradually-varied thickness.

A fiber-reinforced resin composite material has a longitudinal direction, and includes a first stack, a second stack, a ridge, a flat surface, and a connection. The ridge extends in the longitudinal direction. The flat surface is continuous to the ridge. The connection is where the first and second stacks are coupled. The first and second stacks are joined to each other in a direction intersecting the longitudinal direction. Fibers of at least one of first fiber-reinforced resin sheets included in the first stack, fibers of at least one of second fiber-reinforced resin sheets included in the second stack, or both intersect the ridge. The connection includes the first and second fiber-reinforced resin sheets that are overlapped alternately, and includes ends of the first fiber-reinforced resin sheets, ends of the second fiber-reinforced resin sheets, or both that are shifted from each other to allow the connection to have a gradually-varied thickness.

Disclosed herein are devices and methods for manufacturing uncured, near-net shape plies. Such devices include: a plurality of spools, each dispensing a dry tow; optionally, a plurality of spreaders to spread the dry tows; optionally, a means to combine the dry tows into a plurality of tapes or bundles; a plurality of feeders, each carrying a tow, tape or bundle, and adapted to maintain the tows, tapes or bundles in a parallel arrangement; a cutting apparatus adapted to independently cut each individual tow, tape or bundle to a pre-determined length; optionally, a conveyor adapted to transport the cut tows, tapes or bundles away from the cutting apparatus; an in-line resin infuser adapted to impregnate the dry tows, tapes or bundles with resin material; and a receiver for the cut tows, tapes or bundles, wherein the cut tows, tapes or bundles are impregnated and configured in the form of a near-net shape ply.

Disclosed herein are devices and methods for manufacturing uncured, near-net shape plies. Such devices include: a plurality of spools, each dispensing a dry tow; optionally, a plurality of spreaders to spread the dry tows; optionally, a means to combine the dry tows into a plurality of tapes or bundles; a plurality of feeders, each carrying a tow, tape or bundle, and adapted to maintain the tows, tapes or bundles in a parallel arrangement; a cutting apparatus adapted to independently cut each individual tow, tape or bundle to a pre-determined length; optionally, a conveyor adapted to transport the cut tows, tapes or bundles away from the cutting apparatus; an in-line resin infuser adapted to impregnate the dry tows, tapes or bundles with resin material; and a receiver for the cut tows, tapes or bundles, wherein the cut tows, tapes or bundles are impregnated and configured in the form of a near-net shape ply.

A forming module for forming a composite laminate part over a tool is provided. The forming module comprises a base, a ply carrier control assembly adapted for controlling the position of a flexible ply carrier on which composite resin plies are mounted, and a head section mounted on the base and adapted for automatically forming the composite resin plies from the ply carrier onto the tool.

A forming module for forming a composite laminate part over a tool is provided. The forming module comprises a base, a ply carrier control assembly adapted for controlling the position of a flexible ply carrier on which composite resin plies are mounted, and a head section mounted on the base and adapted for automatically forming the composite resin plies from the ply carrier onto the tool.