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 fiber application head comprising a compaction system including a plurality of independent compaction rollers and compaction cylinders and, for each fiber, cutting means and rerouting means. For each fiber, the head comprises a functional module including the cutting means and the rerouting means, each functional module is mounted so as to be movable in translation on a support element of the head. Each compaction roller is mounted on one or more adjacent functional modules. A compaction cylinder is associated with the functional module(s) associated with a compaction roller for the displacement in translation of the functional module(s). An independent heating system is associated with each compaction roller, and able to displace with the functional module(s) associated with a compaction roller.

A system for fabrication of a wind turbine blade including a laser projection which identifies the dimensions for a plurality of layup segments; determines the sequence of layup segments within first and second sections of the mold, wherein the sequence of layup segments within the second section of the mold are synchronized with the layup segments within a first section of the mold. The system also includes a projection device visually depicting the boundaries of a plurality of layup segments onto the mold. This system automates fabrication of composite structures by setting a pace for each task and ensuring operators complete each task within the allotted period. The projection system and layup delivery mechanism can advance with respect the mold to ensure the pace is maintained and an overall product cycle time is adhered to.

A system for fabrication of a wind turbine blade including a laser projection which identifies the dimensions for a plurality of layup segments; determines the sequence of layup segments within first and second sections of the mold, wherein the sequence of layup segments within the second section of the mold are synchronized with the layup segments within a first section of the mold. The system also includes a projection device visually depicting the boundaries of a plurality of layup segments onto the mold. This system automates fabrication of composite structures by setting a pace for each task and ensuring operators complete each task within the allotted period. The projection system and layup delivery mechanism can advance with respect the mold to ensure the pace is maintained and an overall product cycle time is adhered to.

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 method is disclosed for additively manufacturing a structure. The method may include discharging a composite material, including a reinforcement and a matrix, from a print head, and moving the print head during discharging to form the structure from the composite material. The method may further include exposing the composite material during discharging to a cure energy to trigger the matrix to harden, and selectively adding a filler to the composite material to cause the composite material to increase a temperature achieved when the composite material is exposed to the cure energy.

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.

An apparatus and method for the automatic manufacturing of wind turbine blades, including an elongate tool support (2) with a main suspension beam (4), a plurality of support frames (8) supporting the main suspension beam (4) above the wind turbine blade mould (1), an elongate guide rail (5) provided on the main suspension beam (4) so as to extend longitudinally along the main suspension beam (4), a slider base (6) slidably mounted on the guide rail (5), a drive mechanism (53) for driving the slider base (6) longitudinally along the guide rail (5) and a tool holder (7) mounted on the slider base (6). The apparatus/method improves the efficiency and accuracy of the blade manufacture, and also reduces the exposure of the human body to harmful substances used in blade manufacture.

Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.