System for additively manufacturing composite structure

Abstract

A system for additively manufacturing a structure is disclosed. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may have an outlet that is oriented at an oblique angle relative to a central axis of the print head.

What is claimed is: 
     
         1 . A method of additively manufacturing a structure, comprising:
 discharging a material through an outlet of a print head to form a layer of the structure;   orienting an axis of the outlet along a first plane during discharging of a first track of the material in the layer;   moving the print head adjacent the layer in a print direction during discharging of the first track of the material;   orienting the axis of the outlet along a second plane during discharging of a second track of the material in the layer and adjacent to the first track of the material, the second plane being oriented obliquely to the first plane; and   moving the print head adjacent the layer during discharging of the second track of the material.   
     
     
         2 . The method of  claim 1 , wherein the second plane is oriented about 1-60° relative to the first plane. 
     
     
         3 . The method of  claim 1 , wherein discharging the second track of the material includes simultaneously urging the second track of the material against an underlying surface and against the first track of the material. 
     
     
         4 . The method of  claim 1 , further including compacting the material with a compactor trailing behind the outlet. 
     
     
         5 . The method of  claim 4 , further including orienting an axis of the compactor an oblique angle relative to the layer. 
     
     
         6 . The method of  claim 5 , wherein orienting the compactor includes orienting an axis of the compactor at an angle relative to the first plane that is different than the oblique angle at which the axis of the outlet is oriented. 
     
     
         7 . The method of  claim 4 , wherein:
 the compactor is compliant; and   the method further includes deforming the compactor at least partially around the material.   
     
     
         8 . The method of  claim 4 , wherein:
 the compactor is rigid; and   the method further includes allowing the compactor to swivel freely relative to the outlet during compacting of the material.   
     
     
         9 . The method of  claim 4 , further including allowing the compactor to swivel freely relative to the outlet during compacting of the material. 
     
     
         10 . The method of  claim 1 , wherein:
 discharging the material includes discharging a continuous reinforcement that is at least partially coated in a liquid matrix;   the first plane is aligned with the continuous reinforcement in the first track of the material; and   the second plane is aligned with the continuous reinforcement in the second track of the material.   
     
     
         11 . The method of  claim 1 , wherein:
 the first plane extends through the first track of the material; and   the second plane extends through the second track of the material.   
     
     
         12 . A method of additively manufacturing a structure, comprising:
 discharging a material through an outlet of a print head to form a layer of the structure;   orienting an axis of the outlet along a first plane during discharging of a track of the material in the layer, the first plane being perpendicular to the layer;   moving the print head adjacent the layer in a print direction during discharging of the track of the material;   compacting the material with a compactor trailing behind the outlet; and   orienting an axis of the compactor an oblique angle relative to the layer.   
     
     
         13 . The method of  claim 12 , further including orienting the axis of the compactor at an oblique angle relative to the first plane. 
     
     
         14 . The method of  claim 12 , further including discharging of a second track of the material in the layer and adjacent to the track of the material, wherein compacting the material with the compactor includes urging the second track of the material transversely against the track of the material. 
     
     
         15 . The method of  claim 14 , wherein compacting the material with the compactor includes simultaneously urging the second track of the material against an underlying surface and transversely against the track of the material. 
     
     
         16 . The method of  claim 12 , wherein:
 the compactor is compliant; and   the method further includes deforming the compactor at least partially around the material.   
     
     
         17 . The method of  claim 12 , wherein:
 the compactor is rigid; and   the method further includes allowing the compactor to swivel relative to the outlet during compacting of the material.   
     
     
         18 . The method of  claim 12 , further including allowing the compactor to swivel relative to the outlet during compacting of the material. 
     
     
         19 . An additive manufacturing system, comprising:
 a support; and   a print head operatively connected to and moved by the support, the print head having an outlet with an axis lying within a plane; and   a compactor mounted to a trailing side of the print head, the compactor having an axis of rotation that is oriented at an oblique angle relative to the plane.   
     
     
         20 . The additive manufacturing system of  claim 19 , wherein the compactor is configured to swivel relative to the outlet during compacting of material discharging from the outlet.