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.

The invention relates to an FFF printing system (100), the FFF printing system comprising a print head (105), a feeder (91;126) arranged to feed a filament (4) into the print head (105), and a container (801) for storing the filament on one or more filament spools (88). The system also comprises a prefeeder (81) arranged to feed the filament from the spools to the feeder (91;126), and a first flexible tube (D01;102;121) for guiding the filament (4). A filament path length measuring device (1) is arranged to detect a misalignment between the feeder and the prefeeder. Measurement signals are sent to a processing system to correct any misalignment.

A fibre application head for producing composite material parts, comprising a compacting system comprising a compacting roller for applying one or more fibres onto an application surface, and a heating system capable of emitting thermal radiation towards the fibre or fibres. The head further comprises a blowing system comprising an air blowing nozzle, the nozzle being arranged upstream from the roller, with respect to the movement direction, and being capable of forming an air knife, parallel to the axis of the roller, towards the nip zone between the compacting roller and the layup surface.

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.

A fiber placement head for applying a plurality of composite tape segments on a mold including a frame that supplies composite tape for application to the mold is configured to be releasably connected to a robotic arm; a tape application assembly that is slidably carried by the frame and applies the composite tape segments to the mold, wherein the tape application assembly moves linearly from one end of the frame toward another end of the frame along a W-axis

A manufacturing system (1) for manufacturing shaped laminates including: forming tools (2.1, 2.2) extending along a longitudinal direction X, located parallel to one another and configured to receive a laminate (4) between the forming tools; a shaping tool (3) extending along the longitudinal direction X and along a transversal direction Z, and configured to receive the laminate (4) on an external surface of the shaping tool, wherein the forming tools (2.1, 2.2) or the shaping tool (3) are movable in the longitudinal direction X and in the transversal direction Z, relative to the at least one of the shaping tool (3) and the two forming tools (2.1, 2.2).

A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may have a first tool center point associated with discharge of a first material, and a second tool center point associated with discharge of a second material that is a type different than the first material.

An AFP or ATL composites manufacturing head providing one or more fiber element tows under tension to a compaction roller which in operation presses the individual tow(s) onto a substrate to produce a part or tool. Two or more separately controlled heat sources are provided for at least one of the tows and its corresponding substrate to consolidate the tow and substrate.

Disclosed herein is an automated fiber placement system that comprises a robot, an end effector, and a creel assembly that is coupled to the robot and movable with the robot. The creel assembly comprises a spool of a tow and a tow tensioner. The tow tensioner comprises an arm assembly that is pivotable toward and away from a tow direction between a forward position and a rearward position, inclusive, and configured to secure the tow from the spool as the tow unwinds from the spool and moves in the tow direction. The tow tensioner also comprises a biasing member that is coupled to the arm assembly and configured to bias the arm assembly into a neutral position between the forward position and the rearward position. The tow tensioner additionally comprises a potentiometer that is coupled to the arm assembly and configured to detect a position of the arm assembly.