# US 2019/0315055 A1 · System and head for continuously manufacturing composite structure

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- Number: US 2019/0315055 A1
- Document ID: US20190315055A1
- Status: Published application
- Kind: A1
- Application number: 16/279,878
- Filed: 2019-02-19
- Published: 2019-10-17
- Earliest claimed: 2018-04-12
- Assignees: Cc3D LLC
- Applicants: Cc3D LLC
- Inventors: Kenneth Lyle Tyler
- Web page: https://patentgrep.com/patent/US20190315055A1

## CPC

- B29C 64/188: involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control (surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00)
- B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM]
- B29C 64/209: Heads; Nozzles
- B29C 64/307: Handling of material to be used in additive manufacturing
- B29C 64/314: Preparation
- B29C 64/321: Feeding
- B29C 70/16: using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)}
- B29C 70/384: {Fiber placement heads, e.g. component parts, details or accessories}
- B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

## Abstract

A print head is disclosed for use in an additive manufacturing system. The print head may include a discharge outlet configured to discharge a continuous reinforcement, and an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge. The print head may also include a cure enhancer configured to soften the solid film after discharge.

## Claims

### Claim 1

A system for additively manufacturing a composite structure, comprising:
a print head, including:
a discharge outlet configured to discharge a continuous reinforcement; and
an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge;
a support configured to move the print head during discharging; and
a controller configured to selectively activate the support based on known specifications for the composite structure.

### Claim 2 (depends on 1)

The system of claim 1, further including a cure enhancer configured to soften the solid film after discharge.

### Claim 3 (depends on 2)

The system of claim 2, wherein the cure enhancer is mounted to the print head.

### Claim 4 (depends on 2)

The system of claim 2, wherein the print head further includes a matrix chamber configured to apply a matrix coating to the continuous reinforcement prior to application of the solid film.

### Claim 5 (depends on 4)

The system of claim 4, wherein the cure enhancer is further configured to initiate curing of the matrix coating.

### Claim 6 (depends on 5)

The system of claim 5, wherein:
the solid film is at least one of partially transparent and porous; and
the cure enhancer is configured to direct cure energy through the solid film to the matrix coating.

### Claim 7 (depends on 4)

The system of claim 4, wherein:
the solid film is a thermoplastic; and
the matrix coating is a thermoset resin.

### Claim 8 (depends on 4)

The system of claim 4, wherein the applicator is further configured to at least one of remove air bubbles from the matrix coating and press the solid film onto the continuous reinforcement.

### Claim 9 (depends on 4)

The system of claim 4, wherein the print head further includes rollers configured to pull the continuous reinforcement through the matrix chamber.

### Claim 10 (depends on 4)

The system of claim 4, wherein:
the print head further includes a vacuum chamber located between the matrix chamber and the discharge outlet; and
the applicator applies the solid film to the continues reinforcement inside the vacuum chamber.

### Claim 11 (depends on 1)

The system of claim 1, further including an edge fuser configured to fuse edges of the solid film.

### Claim 12 (depends on 11)

The system of claim 11, further including a feeder located downstream of the edge fuser and configured to push the continuous reinforcement and the solid film through the discharge outlet.

### Claim 13 (depends on 1)

The system of claim 1, wherein the applicator is configured to apply the solid film to opposing sides of the continuous reinforcement, such that the continuous reinforcement is sandwiched between layers of the solid film.

### Claim 14 (depends on 1)

The system of claim 1, wherein:
the continuous reinforcement enters the print head already coated in a first matrix; and
the print head further includes a matrix chamber configured to apply a second matrix coating to the continuous reinforcement prior to application of the solid film.

### Claim 15

A print head for an additive manufacturing system, comprising:
a discharge outlet configured to discharge a continuous reinforcement;
an applicator disposed upstream of the discharge outlet and configured to apply a solid film to the continuous reinforcement prior to discharge; and
a cure enhancer configured to soften the solid film after discharge.

### Claim 16 (depends on 15)

The print head of claim 15, further including a matrix chamber configured to apply a matrix coating to the continuous reinforcement prior to application of the solid film, wherein the cure enhancer is further configured to initiate curing of the matrix coating.

### Claim 17 (depends on 16)

The print head of claim 16, wherein:
the solid film is at least one of partially transparent and porous; and
the cure enhancer is configured to direct cure energy through the solid film to the matrix coating.

### Claim 18 (depends on 16)

The print head of claim 16, wherein the applicator is further configured to at least one of remove air bubbles from the matrix coating and press the solid film onto the continuous reinforcement.

### Claim 19 (depends on 16)

The print head of claim 16, further including a vacuum chamber located between the matrix chamber and the discharge outlet, wherein the applicator applies the solid film to the continues reinforcement inside the vacuum chamber.

### Claim 20 (depends on 15)

The print head of claim 15, further including:
an edge fuser configured to fuse edges of the solid film; and
a feeder located downstream of the edge fuser and configured to push the continuous reinforcement and the solid film through the discharge outlet.