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).

The purpose of the present invention is to provide a lightweight composite material structure while suppressing a drop in strength. In a composite material structure, which is configured as a fiber-reinforced plastic composite material extending in one direction and having a plurality of holes (5) formed at intervals in a row in the one direction and which is subjected to a tensile load and/or a compressive load in the one direction, a peripheral region (3a) around the holes (5) comprises a first area (10) obtained by bending composite material, which is reinforced using continuous fibers that have been made even in the longitudinal direction, so that the center line of the width (W) of the composite material weaves between adjacent holes (5) and zigzags in the one direction. The tensile rigidity and/or compressive rigidity in the one direction of the peripheral region (3a) around the holes (5) is lower than the tensile rigidity and/or the compressive rigidity in the one direction of the other regions (3b) that surround the peripheral regions (3a).

A system for making a component having a plurality of layers sequentially deposited via additive manufacturing has a nozzle and a print controller. The nozzle has an orifice. The print controller defines a print pattern for the nozzle for each layer of the component. The print pattern defines a print order in which filaments are deposited from the nozzle to form one of the plurality of layers of the component. A cutter at the orifice of the nozzle is used to cut the filament as required according to the print pattern. The nozzle moves according to the print pattern for the layer of the component being formed and simultaneously coextrude an elastomeric matrix material and a reinforcing material from the orifice of the nozzle as one of the filaments, such that the reinforcing material is entirely internal to the elastomeric matrix material.

A method for manufacturing a multi-perforated acoustic skin out of composite material for an acoustic attenuation structure, the method including forming a fibrous preform including a matrix precursor material, carrying out a heat treatment for transforming the precursor into a matrix so as to obtain a multi-perforated acoustic skin made of composite material including a fibrous reinforcement densified by the matrix, the forming of the fibrous preform including draping fibers on a surface of a mandrel including protuberances, and the mandrel and the protuberances can be each made of a material that melts at a temperature lower than the heat-treatment temperature for transforming the precursor into a matrix in such a way as to eliminate the mandrel and the protuberances during the transforming heat treatment step.

A process for manufacturing a blade made of composite material for a turbomachine is provided. The blade includes an airfoil having a pressure side and a suction side which extend from a leading edge to a trailing edge of the airfoil. The blade further includes a metal sheath that extends along the leading edge of the airfoil. The process includes the steps of: a) placing a preform, made by three-dimensionally weaving fibers, in a mold, a polymerizable adhesive being inserted between the sheath and the edge of the preform; and b) injecting polymerizable resin into the mold to impregnate the preform so as to form the airfoil after solidifying, wherein the resin is injected within a time interval during which the adhesive reaches a freezing point.

A printhead and a heating unit (100) for the printhead are disclosed. The heating unit includes at least two guiding tubes (132, 134) including a first guiding tube (132) adapted for guiding a fiber filament to an extruder (140) of the heating unit and a second guiding tube (134) adapted for guiding a polymer filament to the extruder. The heating unit further includes a heating element (151) adapted for melting the polymer filament and a horizontal guiding channel (125) adapted for guiding the melted polymer from the second guiding tube to the extruder. The heating unit further includes a printing nozzle (123) connected to the extruder and adapted for printing a composite part by outputting the composite material outside of the heating unit.

A composite panel holder having a plurality of layers, wherein each layer is a fiber matrix tape including a plurality of fibers immobilized in a matrix of a thermoplastic or thermoset polymer, and each layer is oriented at a different angle but in a same plane relative to a layer it is in direct contact with; and wherein the composite panel holder comprises six portions oriented in different directions, as viewed along a longitudinal axis of the panel holder. A method of preparing the composite panel holder that includes impregnating a plurality of fibers in a thermoplastic or thermoset polymer to form a matrix of fibers in the polymer, forming the matrix into a plurality of unidirectional tapes, stacking the tapes to form a composite structural panel with each of the tapes oriented in a different direction from adjacent tapes; and pressing the structural panel with a thermoforming press.