Method for rapid prototyping of solid models

Data corresponding to a desired shape of a prototype is transmitted to a rapid prototyping system. The system calculates a sequence for extruding flowable material that thermally solidifies so as to create the desired geometric shape. A heated flowable modeling material is then sequentially extruded at its deposition temperature into a build environment that maintains the volume in the vicinity of the newly deposited material in a deposition temperature window between the material's solidification temperature and its creep temperature. Subsequently the newly extruded material is gradually cooled below its solidification temperature, while maintaining temperature gradients in the geometric shape below a maximum value set by the desired part's geometric accuracy.

FILAMENT CASSETTE

Method and apparatus for solid prototyping

An improved extrusion-based manufacturing system includes one or more extruders, with each extruder containing at least two stages of increasing pressurization. In a preferred embodiment, a first stage of pressurization is created by the motion of a solid wafer of thermoplastic through an orifice into a heater chamber. In another preferred embodiment, the wafers are stored in removable, electronically tagged, cassettes and are removed therefrom by a stapler mechanism which feeds the wafers from the cassette to a tractor feed mechanism on demand. In each embodiment, a second stage of pressurization is provided by a pump, with the first stage pressurization maintaining a flow of thermoplastic to the pump under all expected pump rates.

MULTIPLE-ZONE LIQUEFIER ASSEMBLY FOR EXTRUSION-BASED ADDITIVE MANUFACTURING SYSTEMS

A liquefier assembly for use in an extrusion-based additive manufacturing system, and a method for building a three-dimensional model with the extrusion-based additive manufacturing system, where the liquefier assembly includes a liquefier tube having multiple, independently heatable zones along a longitudinal length of the liquefier tube. 1. A liquefier assembly for use in an extrusion-based additive manufacturing system , the liquefier assembly comprising:a liquefier tube having a first end and a second end offset along longitudinal length;an extrusion tip secured to the first end of the liquefier tube;a first thermal unit operably secured to the liquefier tube adjacent the first end of the liquefier tube; anda second thermal unit operably secured to the liquefier tube between the first thermal unit and the second end of the liquefier tube, wherein the first thermal unit and the second thermal unit are configured to be operated independently of each other.2. The liquefier assembly of claim 1 , wherein the first thermal unit comprises:a first thermally-conductive component in thermal contact with an outer surface of the liquefier tube; anda first electrically-conductive component configured to heat the first thermally-conductive component;3. The liquefier assembly of claim 2 , wherein the first thermal unit further comprises a first temperature sensor configured to detect a temperature of at least one of the first thermally-conductive component claim 2 , the liquefier tube at a location adjacent to the first thermally-conductive component claim 2 , and a combination thereof.4. The liquefier assembly of claim 2 , wherein the second thermal unit comprises:a second thermally-conductive component in thermal contact with the outer surface of the liquefier tube; anda second electrically-conductive component configured to heat the second thermally-conductive component.5. The liquefier assembly of claim 4 , wherein the second thermal unit further comprises a second ...

Three-Dimensional Parts Having Porous Protective Structures

Three-dimensional parts having porous protective structures built with powder-based additive manufacturing systems, the porous protective structures being configured to protect the three-dimensional parts from damage during de-powdering processes.

Method for building three-dimensional models with extrusion-based additive manufacturing systems

A method for building a three-dimensional model with an extrusion-based additive manufacturing system having an extrusion head, the method comprising depositing a consumable material from a liquefier assembly at an extrusion rate to substantially normalize a meniscus height within the liquefier assembly.

LIQUEFIER ASSEMBLY FOR USE IN EXTRUSION-BASED ADDITIVE MANUFACTURING SYSTEMS

A liquefier assembly for use in an extrusion-based additive manufacturing system, the liquefier assembly comprising a downstream portion having a first average inner cross-sectional area, and an upstream having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion defining a shoulder configured to restrict movement of a melt meniscus of a consumable material. 1. A liquefier assembly for use in an extrusion-based additive manufacturing system , the liquefier assembly comprising:a downstream portion comprising a first end and a second end opposite of the first end along a longitudinal length of the liquefier assembly, wherein the downstream portion has a first average inner cross-sectional area;an upstream portion disposed adjacent to the first end of the downstream portion, the upstream portion being configured to receive a consumable material,wherein the upstream portion has a second average inner cross-sectional area that is less than the first inner cross-sectional area, and wherein the upstream portion defines a shoulder between the first inner cross-sectional area and the second inner cross-sectional area, the shoulder being configured to restrict movement of a melt meniscus of the consumable material; andan extrusion tip disposed at the second end of the downstream portion.2. The liquefier assembly of claim 1 , wherein the upstream portion comprises an inner surface having a surface energy less than about 75 millinewtons/meter.3. The liquefier assembly of claim 1 , wherein the first average inner cross-sectional area is at least 105% of the second average inner cross-sectional area.4. The liquefier assembly of claim 3 , wherein the first average inner cross-sectional area ranges from about 110% of the second average inner cross-sectional area to about 150% of the second average inner cross-sectional area.5. The liquefier assembly of claim 1 , wherein the upstream portion comprises:a liquefier ...

SEMI-CRYSTALLINE CONSUMABLE MATERIALS FOR USE IN EXTRUSION-BASED ADDITIVE MANUFACTURING SYSTEMS

A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a first portion of a first semi-crystalline polymeric material, and a second portion of a second semi-crystalline polymeric material, and where the second semi-crystalline polymeric material has a crystallization temperature that is greater than a crystallization temperature of the first semi-crystalline polymeric material. 1. A consumable filament for use in an extrusion-based additive manufacturing system , the consumable filament comprising:a first portion extending along a longitudinal length of the consumable filament, the first portion compositionally comprising a first semi-crystalline polymeric material having a first peak crystallization temperature; anda second portion extending along the longitudinal length of the consumable filament and at least partially encasing the first portion, the second portion compositionally comprising a second semi-crystalline polymeric material having a second peak crystallization temperature that is greater than the first peak crystallization temperature, wherein the consumable filament has an average cross-sectional area ranging from about 0.5 square millimeters to about 8 square millimeters, and wherein the second portion has an average volume ranging from about 5% to about 50% of an average volume of the consumable filament.2. The consumable filament of claim 1 , wherein the second peak crystallization temperature is greater than the first peak crystallization temperature by at least about 5° C.3. The consumable filament of claim 2 , wherein the first portion and the second portion are coextruded portions.4. The consumable filament of claim 1 , wherein the average volume of the second portion ranges from about 5% to about 75% of the average volume of the consumable filament.5. The consumable filament of claim 1 , wherein the average cross-sectional area of the consumable filament ranges from about 1 ...

Voice coil mechanism for use in additive manufacturing system

A print head assembly that includes a receptacle supported from a carriage frame and configured to receive a print head, and a toggle mechanism configured to move the receptacle relative to the carriage frame.

PRINT HEAD FOR USE IN FUSED DEPOSITION MODELING SYSTEM

A print head for use in a fused deposition modeling system, the print head includes a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly. 1. A print head for use in a fused deposition modeling system , the print head comprising:a liquefier pump assembly;a housing body; anda housing cover configured to attach to the housing body to define a cartridge assembly, wherein the liquefier pump assembly is retained by the cartridge assembly.2. The print head of claim 1 , wherein the liquefier pump assembly comprises:a drive block retained within the cartridge assembly, and having a first opening and a second opposing opening, the first and second openings being offset by a channel that is configured to receive a filament of a material;a rotatable shaft retained within the cartridge assembly, and having a toothed surface extending at least partially within the channel of the drive block, the toothed surface being configured to engage the received filament;a filament tube having a first end and a second end, wherein the first end extends into the second opening of the drive block; anda liquefier coupled to the second end of the filament tube.3. The print head of claim 2 , and further comprising:a motor;a rotatable gear axially connected to the motor, and having a threaded surface; anda capstan gear having a rotational axis and perimeter teeth, the perimeter teeth being configured to engage the threaded surface of the rotatable gear, wherein the rotatable shaft extends from the rotational axis of the capstan gear.4. The print head of claim 1 , wherein the first opening of the drive block is configured to engage with a filament guide tube.5. The print head of claim 1 , wherein at least one of the housing body and the housing cover comprises a vent.6. The print head of claim 1 , and further comprising a circuit board secured to the housing cover claim 1 , the circuit board being electrically connected to the liquefier pump assembly.7. The print ...

PRINT HEAD ASSEMBLY FOR USE IN FUSED DEPOSITION MODELING SYSTEM

A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. 1. A print head assembly for use in a fused deposition modeling system , the print head assembly comprising:a carriage frame configured to be retained by a gantry mechanism of the fused deposition modeling system; anda receptacle supported from the carriage frame such that the receptacle is moveable relative to the carriage frame along at least one axis, wherein the receptacle is configured to securely retain a removable print head in a manner that prevents the retained print head from moving relative to the receptacle during operation of the fused deposition modeling system.2. The print head assembly of claim 1 , wherein the receptacle is supported from the carriage frame with at least one suspension mechanism that is configured to restrict movement of the receptacle relative to the carriage frame to directions substantially along a single axis of the at least one axis.3. The print head assembly of claim 2 , wherein the at least one suspension mechanism comprises at least one flexure member.4. The print head assembly of claim 1 , and further comprising a toggle mechanism configured to move the receptacle relative to the carriage frame along the at least one axis.5. The print head assembly of claim 4 , wherein the toggle mechanism comprises a voice coil.6. The print head assembly of claim 1 , and further comprising an encoder assembly configured to measure the position of the receptacle relative to the carriage frame along the at least one axis.7. The print head assembly of claim 1 , wherein the receptacle comprises a vent opening claim 1 , and wherein the print head assembly further comprises a cooling unit configured to direct air through the vent opening to the print head when the print head is received in the base portion.8. The print head assembly of claim 1 , wherein the ...

PRINT HEAD ASSEMBLY AND PRINT HEAD FOR USE IN FUSED DEPOSITION MODELING SYSTEM

A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly. 1. A print head assembly for use in a fused deposition modeling system , the print head assembly comprising:a carriage frame configured to be retained by a gantry mechanism of the fused deposition modeling system;a receptacle configured to securely retain a removable print head in a manner that prevents the retained print head from moving relative to the receptacle during operation of the fused deposition modeling system;at least one suspension mechanism operably connected to the carriage frame, wherein the receptacle is supported by the at least one suspension mechanism, and wherein the at least one suspension mechanism is configured to restrict movement of the receptacle relative to the carriage frame to directions substantially along a single axis; anda toggle mechanism configured to move the receptacle relative to the carriage frame in the directions substantially along the single axis.2. The print head assembly of claim 1 , wherein the at least one suspension mechanism comprises at least one flexure member.3. The print head assembly of claim 1 , wherein the at least one suspension mechanism comprises a linear bearing having a bearing rail operably mounted to the carriage frame and slide element movably engaged to the bearing rail claim 1 , wherein the receptacle is secured to the slide element.4. The print head assembly of claim 1 , wherein the at least one suspension mechanism comprises a central beam operably mounted to the carriage frame and a plurality of ball bearings retained by the central beam and engaged with the receptacle to provide five degrees of constraint on the movement of the receptacle.5. The print head assembly of claim 1 , wherein the toggle ...

METHOD OF USING PRINT HEAD ASSEMBLY IN FUSED DEPOSITION MODELING SYSTEM

A method of using a print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. 1. A method for building a three-dimensional part with a fused deposition modeling system having a print head carriage , the method comprising:loading a print head to a receptacle of the print head carriage, the receptacle being supported from a carriage frame of the print head carriage;actuating a snap-fit mechanism to secure the loaded print head to the receptacle;feeding a material with the secured print head;melting the fed material in the secured print head;extruding the molten material from the secured print head to form at least a portion of the three-dimensional part; andremoving the print head from the receptacle.2. The method of claim 1 , and further comprising moving the receptacle containing the secured print head relative to the carriage frame along at least one axis.3. The method of claim 2 , and further comprising restricting the movement of the receptacle containing the secured print head to directions substantially along a single axis of the at least one axis.4. The method of claim 2 , and further comprising measuring positions of the receptacle along the at least one axis with an encoder assembly.5. The method of claim 1 , wherein loading the print head to the receptacle comprises aligning the print head with alignment features of the receptacle.6. The method of claim 1 , and further comprising communicating between the secured print head and a control board retained by the carriage frame through an electrical circuit retained by the receptacle.7. The method of claim 1 , and further comprising forcing an air flow through the receptacle and into the secured print head.8. The method of claim 1 , and further comprising:loading a second print head to a second receptacle of the print head carriage, the second receptacle being supported from the carriage ...

Core-shell consumable materials for use in extrusion-based additive manufacturing systems

A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.

ADDITIVE MANUFACTURING SYSTEM AND METHOD FOR PRINTING CUSTOMIZED CHOCOLATE CONFECTIONS

An additive manufacturing system for printing a chocolate confection, the system comprising a platen, a recirculation loop configured to circulate a flow of a chocolate material, and further configured to maintain a temper of the chocolate material; and a print head the print head being configured to receive at least a portion of the chocolate material from the recirculation loop, and further configured to extrude and deposit the chocolate material onto the platen to print at least a portion of the chocolate confection based on the commands from a controller. 1. An additive manufacturing system for printing a chocolate confection , the additive manufacturing system comprising:at least one controller configured to receive instructions for printing the chocolate confection, and further configured to relay commands relating to the received instructions;a platen;a recirculation loop configured to circulate a flow of a chocolate material, and further configured to maintain a temper of the chocolate material; anda print head in signal communication with the at least one controller, the print head being configured to receive at least a portion of the chocolate material from the recirculation loop, and further configured to extrude and deposit the chocolate material onto the platen to print at least a portion of the chocolate confection based on the commands from the at least one controller.2. The additive manufacturing system of claim 1 , wherein the recirculation loop comprises:a shear tank configured to heat and shear the chocolate material; anda pump configured pump the flow of the chocolate material from the sheer tank to the print head.3. The additive manufacturing system of claim 2 , wherein the shear tank is maintained at a set point temperature ranging from about 82° F. to about 90° F.4. The additive manufacturing system of claim 2 , wherein the shear tank is configured to receive a cartridge of tempered solid chocolate material.5. The additive manufacturing system ...

ADDITIVE MANUFACTURING SYSTEM AND METHOD WITH INTERCHANGEABLE CARTRIDGES FOR PRINTING CUSTOMIZED CHOCOLATE CONFECTIONS

An additive manufacturing system for printing a chocolate confection, the system comprising a platen, a print head, and a cartridge configured to be removably secured to the print head, wherein the cartridge contains a supply of the chocolate material. 1. An additive manufacturing system for printing a chocolate confection , the system comprising:at least one controller configured to receive instructions for printing the chocolate confection, and further configured to relay commands relating to the received instructions;a platen;a print head, wherein at least one of the platen and the print head is movable such that the platen and the print head move relative to each other based on commands from the controller; anda cartridge configured to be removably secured to the print head, wherein the cartridge contains a supply of the chocolate material, and wherein the print head is configured to extrude the chocolate material onto the platen to build the three-dimensional part using a layer-based, additive manufacturing technique in a duration that prevents the chocolate material from thickening past a viscosity threshold of the chocolate material.2. The additive manufacturing system of claim 1 , wherein the duration is 60 minutes or less.3. The additive manufacturing system of claim 2 , wherein the duration is 50 minutes or less.4. The additive manufacturing system of claim 1 , wherein the supply of the chocolate material is pre-tempered.5. The additive manufacturing system of claim 1 , wherein the cartridge comprises:a compressible bellows reservoir configured to contain the supply of the chocolate material; andan extrusion tip secured to the compressible bellows reservoir.6. The additive manufacturing system of claim 5 , wherein the print head comprises:a rotatable drive wheel; anda tracked shaft configured to engage the rotatable drive wheel, wherein the tracked shaft is configured to operably engage the compressible bellows reservoir.7. The additive manufacturing ...

RIBBON FILAMENT AND ASSEMBLY FOR USE IN EXTRUSION-BASED DIGITAL MANUFACTURING SYSTEMS

A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.

EXTRUSION-BASED ADDITIVE MANUFACTURING PROCESS WITH PART ANNEALING

A method for building a three-dimensional part, the method comprising providing a printed three-dimensional part and support structure, where the support structure comprises at least two polymers having different glass transition temperatures. The method also comprises annealing the three-dimensional part. 1. A method for printing a three-dimensional part with an extrusion-based additive manufacturing system , the method comprising:printing a support structure from a support material with the extrusion-based additive manufacturing system using a layer-based additive manufacturing technique, wherein the support material comprises at least two polymers having different glass transition temperatures and that are substantially immiscible with each other;in coordination with the printing of the support structure, printing the three-dimensional part from a part material with the extrusion-based additive manufacturing system using the layer-based additive manufacturing technique;heating the printed support structure and the printed three-dimensional part to at least one temperature that is above a glass transition temperature of the part material, and that is below a glass transition temperature of at least one of the polymers of the support material; andcooling the heated support structure and the heated three-dimensional part.2. The method of claim 1 , wherein the at least two polymers of the support material comprise:a first polymer having a first glass transition temperature; anda second polymer having a second glass transition temperature that is greater than the first glass transition temperature of the first polymer by at least about 10° C.3. The method of claim 2 , wherein the second glass transition temperature of the second polymer is at least about 20° C. greater than the first glass transition temperature of the first polymer.4. The method of claim 1 , wherein the at least two polymers of the support material comprise:at least one first polymer having a first ...

Solid identification grid engine for calculating support material volumes, and methods of use

A method for calculating a support material volume, the method comprising generating a grid of cells for a tree data structure of a digital part, where the cells define a plurality of cell arrays, and pinging the cells of one of the cell arrays until a cell containing a subset of the tree data structure is reached or until each cell in the cell array is pinged, where if a cell containing the subset of the tree data structure is reached, then designating the reached cell and all remaining unpinged cells in the cell array as filled. The method also includes repeating the pinging step for each remaining cell array to determine a total filled volume, and subtracting a volume of the digital part from the total filled volume to determine a support material volume.

Layer Transfusion with Rotatable Belt for Additive Manufacturing

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.

Layer Transfusion with Transfixing for Additive Manufacturing

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part. 1. An additive manufacturing system for printing a thermoplastic part , the additive manufacturing system comprising:an imaging engine configured to develop imaged layers of a thermoplastic-based powder;a movable build platform;a transfer medium having a transfer surface configured to sequentially receive and convey the imaged layers from the imaging engine to the build platform and an opposing contact surface;a heater configured to heat the imaged layers on the transfer medium to a fusion temperature;a layer transfuse element configured to be heated to a transfer temperature and further configured to transfuse a heated imaged layer conveyed by the transfer medium onto previously fused layers of a thermoplastic part being printed by engaging the contact surface, and to disengage from the contact surface without releasing the transfer medium from the transfused layer; anda cooling unit configured to actively cool the transfused layer while it remains on the transfer medium.2. The additive manufacturing system of claim 1 , wherein the layer transfuse element comprises a press plate.3. The additive manufacturing system of claim 2 , wherein the moveable build platform is configured to release the transfer medium from the transfused layer by moving away from the transfer medium.4. The additive manufacturing system of claim 1 , wherein the transfer medium comprises a rotatable belt.5. The additive manufacturing system of claim 4 , wherein the rotatable belt revolves in a rotational path from the imagine engine claim 4 , past the heater claim 4 , in between the layer transfuse element and build ...

LAYER TRANSFUSION FOR ADDITIVE MANUFACTURING

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part. 1. An additive manufacturing system for printing a three-dimensional part , the additive manufacturing system comprising:a transfer medium configured to receive and transfer imaged layers of a thermoplastic-based powder from an imaging engine;a heater configured to heat the imaged layers on the transfer medium to at least a fusion temperature of the thermoplastic-based powder;a layer transfusion assembly comprising a build platform, the layer transfusion assembly being configured to transfuse the heated layers in a layer-by-layer manner onto the build platform to print the three-dimensional part; anda cooling unit configured to actively cool the transfused layers to hold the printed three-dimensional part at about an average part temperature that is below a deformation temperature of the three-dimensional part.2. The additive manufacturing system of claim 1 , wherein the imaging engine comprises an electrophotography engine claim 1 , and wherein the additive manufacturing system further comprises the electrophotography engine claim 1 , which is configured to develop the imaged layers from the thermoplastic-based powder.3. The additive manufacturing system of claim 1 , wherein the layer transfusion assembly comprises a heatable press plate configured to transfuse the heated layers to previously transfused layers of the printed three-dimensional part.4. The additive manufacturing system of claim 1 , wherein the transfer medium comprises a multiple-layer belt.5. The additive manufacturing system of claim 1 , wherein the transfer medium comprises a rotatable transfer medium claim 1 , and wherein ...

Support Structure Removal System

A support structure removal system comprising a vessel and a second component. The vessel comprises a vessel body, a porous floor configured to retain a three-dimensional part, and an impeller rotatably mounted below the porous floor. The second component comprises a surface configured to operably receive the vessel, and a rotation-inducing assembly located below the surface, where the rotation-inducing assembly is configured to rotate the impeller with magnetic fields when the vessel is received on the surface of the second component to agitate and direct flows of an aqueous fluid through the porous floor. 1. A support structure removal system comprising: a vessel body having a top opening, the vessel body being configured to retain an aqueous fluid;', 'a porous floor supported by the vessel body, wherein the porous floor is configured to retain a three-dimensional part inserted through the top opening; and', 'an impeller rotatably mounted below the porous floor; and, 'a vessel comprising a surface configured to operably receive the vessel; and', 'a rotation-inducing assembly located below the surface, the rotation-inducing assembly being configured to rotate the impeller with magnetic fields when the vessel is received on the surface of the second component to agitate and direct flows of the aqueous fluid through the porous floor., 'a second component comprising2. The support structure removal system of claim 1 , and further comprising at least one heating element configured to heat the aqueous fluid.3. The support structure removal system of claim 1 , wherein the rotation-inducing assembly is configured to rotate the impeller with the magnetic fields in a first rotation direction and a second rotational direction that is counter to the first rotational direction.4. The support structure removal system of claim 1 , wherein the rotation-inducing assembly comprises a magnet assembly claim 1 , and wherein the support structure removal system further comprises a ...

ELECTROPHOTOGRAPHY-BASED ADDITIVE MANUFACTURING SYSTEM WITH RECIPROCATING OPERATION

An additive manufacturing system for printing a three-dimensional part using electrophotography, the additive manufacturing system comprising a rotatable photoconductor component, first and second development stations configured to develop layers of materials on a surface of the rotatable photoconductor component while the rotatable photoconductor component rotates in opposing rotational directions, and a platen configured to operably receive the developed layers in a layer-by-layer manner to print the three-dimensional part from at least a portion of the received layers. 1. An additive manufacturing system for printing a three-dimensional part using electrophotography , the additive manufacturing system comprising:a rotatable photoconductor component having a surface, and configured to rotate in a first rotational direction and a second rotational direction that is opposite of the first rotational direction;a first development station configured to develop a layer of a first material on the surface of the rotatable photoconductor component while the rotatable photoconductor component rotates in the first rotational direction;a second development station configured to develop a layer of a second material on the surface of the rotatable photoconductor component while the rotatable photoconductor component rotates in the second rotational direction;a rotatable transfer component having a surface configured to receive the developed layers from the surface of the rotatable photoconductor component while rotating in a direction counter to the rotational direction of the rotatable photoconductor component;a platen movable along an x-axis and a z-axis and configured to receive the developed layers from the rotatable transfer component in a layer-by-layer manner to print the three-dimensional part from at least a portion of the received layers; anda controller configured to selectively rotate the rotatable photoconductor component in the first and second rotational ...

ELECTROPHOTOGRAPHY-BASED ADDITIVE MANUFACTURING SYSTEM WITH TRANSFER-MEDIUM SERVICE LOOPS

An additive manufacturing system for printing a three-dimensional part using electrophotography, the additive manufacturing system comprising a rotatable photoconductor component, a development station configured to develop layers of a material on a surface of the rotatable photoconductor component, a rotatable transfer medium configured to receive the developed layers from the surface of the rotatable photoconductor component, and a platen configured to receive the developed layers from the rotatable transfer medium in a layer-by-layer manner. The additive manufacturing system also comprises a plurality of service loops configured to move portions of the rotatable transfer medium at different line speeds while maintaining a net rotational rate of full rotations of the rotatable transfer medium at a substantially steady state. 1. An additive manufacturing system for printing a three-dimensional part using electrophotography , the additive manufacturing system comprising:a rotatable photoconductor component having a surface;a development station configured to develop layers of a material on the surface of the rotatable photoconductor component;a rotatable transfer medium configured to receive the developed layers from the surface of the rotatable photoconductor component;a platen configured to receive the developed layers from the rotatable transfer medium in a layer-by-layer manner to print the three-dimensional part from at least a portion of the received layers from the rotatable transfer medium; anda plurality of service loops configured to move portions of the rotatable transfer medium at different line speeds while maintaining a net rotational rate of full rotations of the rotatable transfer medium at a substantially steady state.2. The additive manufacturing system of claim 1 , wherein the different line speeds comprise a first constant rate line speed and a second intermittent line speed.3. The additive manufacturing system of claim 1 , wherein at least one ...

Layer Transfusion with Part Heating for Additive Manufacturing

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part. 1. An additive manufacturing system for printing a thermoplastic part , the additive manufacturing system comprising:an imaging engine configured to develop imaged layers of a thermoplastic-based powder having a fusion temperature;a movable build platform;a transfer medium having a transfer surface configured to sequentially receive and convey the imaged layers from the imaging engine to the build platform, and having an opposing contact surface;a heater configured to heat the imaged layers on the transfer medium to at least the fusion temperature;a heater configured to heat a previously transfused layer of a thermoplastic part being printed on the build platform to at least the fusion temperature;a heated layer transfusion element configured to transfuse a heated imaged layer conveyed by the transfer medium onto the heated previously fused layer by engaging the contact surface of the transfer medium so that the transfer medium and the heated imaged layer are pressed between the transfuse element and the build platform, and to disengage therefrom without releasing the transfer medium from the transfused layer; anda cooling unit configured to actively cool the transfused layer to below the fusion temperature while it remains on the transfer medium, so as to transfix the transfused layer before delaminating it from the transfer medium.2. The additive manufacturing system of claim 1 , wherein the layer transfusion element is heated to the fusion temperature.3. The additive manufacturing system of claim 1 , wherein the layer transfusion element comprises a press plate.4. The additive ...

GANTRY ASSEMBLY FOR USE IN ADDITIVE MANUFACTURING SYSTEM

A gantry assembly for use in an additive manufacturing system, the gantry assembly comprising a first bearing shaft, a carriage slidably engaged with the first bearing shaft, and a second bearing shaft operably supported by the carriage, the second linear bearing extending along a second axis. The gantry assembly also comprises a tool-head mount slidably engaged with the second linear bearing, a drive belt secured to the tool-head mount, a first motor having a first drive shaft engaged with the drive belt, and a second motor having a second drive shaft engaged with the drive belt. 1. A gantry assembly comprising:a first bearing shaft extending along a first axis;a carriage slidably engaged with the first bearing shaft;a second bearing shaft operably supported by the carriage, the second bearing shaft extending along a second axis that defines a plane with the first axis;a tool-head mount slidably engaged with the second bearing shaft;a drive belt secured to the tool-head mount;a first motor having a first drive shaft engaged with the drive belt; anda second motor having a second drive shaft engaged with the drive belt, wherein the first motor and the second motor are configured to operate independently to rotate the drive belt in manners that move the carriage along the first bearing shaft and that move the head-tool mount along the second bearing shaft based on relative rotational directions and rotational rates between the first drive shaft and the second drive shaft, so as to allow movement of the tool-head mount to any coordinate location within the plane, wherein the gantry assembly is configured to reduce pivoting of the carriage in the plane.2. The gantry assembly of claim 1 , and further comprising:a first pulley engaged with the drive belt, the first pulley being offset along the first axis from the first motor; anda second pulley engaged with the drive belt, the second pulley being offset along the first axis from the second motor, and offset along the ...

SEAM CONCEALMENT FOR THREE-DIMENSIONAL MODELS

A three-dimensional model built with an extrusion-based digital manufacturing system, and having a perimeter based on a contour tool path that defines an interior region of a layer of the three-dimensional model, where at least one of a start point and a stop point of the contour tool path is located within the interior region of the layer. 1. A three-dimension model built with an extrusion-based digital manufacturing system , the three-dimension model comprising a plurality of layers of an extruded material , wherein at least one of the layers comprises:a perimeter of the extruded material, the perimeter comprising a start point and a stop point; andan interior region of the layer defined by the perimeter, wherein at least one of the start point and the stop point is located within the interior region of the layer.2. The three-dimensional model of claim 1 , wherein the location of the at least one of the start point and the stop point is offset from a centerline of the perimeter of the layer by a distance that is greater than about 50% of a road width of the perimeter.3. The three-dimensional model of claim 2 , wherein the distance ranges from greater than about 50% of the road width to about 200% of the road width.4. The three-dimensional model of claim 1 , wherein the start point and the stop point are each located within the interior region of the layer.5. The three-dimensional model of claim 1 , wherein the locations of the start point and the stop point define an arrangement selected from the group consisting of an open-square arrangement claim 1 , a closed-square arrangement claim 1 , an overlapped closed-square arrangement claim 1 , an open-triangle arrangement claim 1 , a closed-triangle arrangement claim 1 , a converging-point arrangement claim 1 , an overlapped-cross arrangement claim 1 , and combinations thereof.6. The three-dimensional model of claim 1 , wherein the perimeter comprises at least one step-over arrangement between the start point and the ...

CONSUMABLE ASSEMBLY WITH PAYOUT TUBE FOR ADDITIVE MANUFACTURING SYSTEM

A payout tube for enabling payout of a consumable filament from a consumable assembly that is configured for use with an additive manufacturing system, the payout tube comprising a tip end having an inlet opening, a base end having an outlet opening, and a tube body having an average effective outer diameter that is substantially greater than an effective inner diameter of the inlet opening. 1. A payout tube for enabling payout of a consumable filament from a consumable assembly that is configured for use with an additive manufacturing system , the payout tube comprising:a tip end having an inlet opening with an effective inner diameter less than about 7.6 millimeters, wherein the inlet opening also has a cross-sectional area ranging from about 110% to about 300% of an average cross-sectional area of the consumable filament;a base end having an outlet opening; anda tube body extending along a longitudinal length between the tip end and the base end, the tube body having an average effective outer diameter along the longitudinal length that is at least about three times greater than the effective inner diameter of the inlet opening.2. The payout tube of claim 1 , wherein longitudinal length of the tube body ranges from about 130 millimeters to about 250 millimeters claim 1 , and wherein the average effective outer diameter ranges from about 38 millimeters to about 130 millimeters.3. The payout tube of claim 1 , wherein the tube body has an outer geometry that is cylindrical or conical between the tip end and the base end.4. The payout tube of claim 1 , wherein the tube body has an outer geometry that comprises a plurality of ribs that extend along the longitudinal length between the tip end and the base end.5. The payout tube of claim 1 , and further comprising a capture tip secured to the tip end of the tube body at least partially within the inlet opening claim 1 , wherein the effective inner diameter of the inlet opening is an inner diameter of the capture tip ...

SPOOL ASSEMBLY WITH LOCKING MECHANISM FOR ADDITIVE MANUFACTURING SYSTEM, AND METHODS OF USE THEREOF

A spool assembly comprising a housing structure, a spool rotatably retained in an interior region of the housing structure, and a sealed sheath encasing the housing structure to define a barrier for the encased housing structure and the rotatably retained spool. The spool assembly further comprises a locking arm disposed outside of the sealed sheath and configured to operably engage the spool through the sealed sheath and through the housing structure in a manner that does not penetrate the sealed sheath, where the locking arm prevents the spool from rotating relative to the housing mechanism when operably engaged with the spool. The locking arm may disengage from the spool in a hands-free manner when the spool assembly is loaded into a bay of an additive manufacturing system. 1. A spool assembly comprising:a housing structure having an interior region;a spool rotatably retained in the interior region of the housing structure;a sealed sheath encasing the housing structure to define a barrier for the encased housing structure and the rotatably retained spool; anda locking arm disposed outside of the sealed sheath and configured to operably engage the spool through the sealed sheath and through the housing structure in a manner that does not penetrate the sealed sheath, wherein the locking arm prevents the spool from rotating relative to the housing mechanism when operably engaged with the spool.2. The spool assembly of claim 1 , wherein the locking arm is configured to actuate between an engaged state in which the locking arm is operably engaged with the spool and a disengaged state in which the locking arm is disengaged from the spool.3. The spool assembly of claim 1 , and further comprising a handle secured to the sealed sheath claim 1 , the handle being separate from the housing structure claim 1 , wherein the locking arm is moveably connected to the handle.4. The spool assembly of claim 1 , wherein the spool comprises:a shaft having a first end and a second end ...

SPOOL ASSEMBLY FOR ADDITIVE MANUFACTURING SYSTEM, AND METHODS OF MANUFACTURE AND USE THEREOF

A spool assembly for use in an additive manufacturing system, comprising a spool rotatably retained in a sealed sheath in a hub-less manner, and a locking mechanism configured to operably engage with the spool to prevent the spool from rotating. 1. A spool assembly comprising:a housing structure having an interior region; a filament-receiving shaft having a first end and a second end offset along the first axis of rotation;', 'a first flange extending from the first end of the filament-receiving shaft, wherein the first flange comprises a first perimeter edge; and', 'a second flange extending from the second end of the filament-receiving shaft, wherein the second flange comprises a second perimeter edge;, 'a spool having a first axis of rotation, and being configured to reside in the interior region of the housing structure in a manner that is free or substantially free of any hub engagement, wherein the spool comprisesa first bearing support mounted to the housing structure within the interior region; anda second bearing support mounted to the housing structure within the interior region at an offset location from the first bearing support, wherein the first bearing support and the second bearing support are configured to support the first perimeter edge of the first flange and the second perimeter edge of the second flange while the spool is rotated around the first axis of rotation.2. The spool assembly of claim 1 , wherein the first bearing support comprises first bearing roller rotatably mounted to the housing structure and having a second axis of rotation that is substantially parallel to the first axis of rotation of the spool.3. The spool assembly of claim 2 , wherein the second bearing support comprises second bearing roller rotatably mounted to the housing structure and having a third axis of rotation that is substantially parallel to the first axis of rotation of the spool.4. The spool assembly of claim 1 , and further comprising a consumable filament ...

UNIVERSAL ADAPTER FOR CONSUMABLE ASSEMBLY USED WITH ADDITIVE MANUFACTURING SYSTEM

A universal adapter for use with a consumable assembly that is configured for use with an additive manufacturing system, the universal adapter comprising an inlet opening configured to receive a guide tube of the consumable assembly, and a connection member at the outlet end, which is configured interface with a mating panel of the additive manufacturing system. 1. A universal adapter for use with a consumable assembly that is configured for use with an additive manufacturing system having a print head and a mating panel that is disposed at remote location from a print head , the universal adapter comprising:an adapter housing having an inlet end and an outlet end;an inlet opening at the inlet end configured to receive a guide tube of the consumable assembly; and a coupling mechanism configured to secure the connection member to the mating panel; and', 'an outlet orifice configured to engage a reciprocating opening of the mating panel., 'a connection member at the outlet end, which is configured interface with the mating panel, the connection member comprising2. The universal adapter of claim 1 , wherein the connection member further comprises a first electrical contact configured to engage a second electrical contact of the mating panel.3. The universal adapter of claim 1 , wherein the electrical contact of the adapter interface is configured to relay electrical power from the additive manufacturing system to the universal adapter.4. The universal adapter of claim 1 , and further comprising a filament drive mechanism retained within the adapter housing.5. The universal adapter of claim 1 , wherein the coupling mechanism comprises a plurality of magnets.6. The universal adapter of claim 1 , and further comprising a filament detection switch retained in the adapter housing.7. The universal adapter of claim 1 , wherein the adapter housing comprises a user grip portion.8. A consumable assembly for use with an additive manufacturing system having a print head and a ...

CONSUMABLE ASSEMBLY FOR USE IN EXTRUSION-BASED LAYERED DEPOSITION SYSTEMS

A consumable assembly comprising a container portion configured to retain a supply of filament, a guide tube connected to the container portion, and a pump portion connected to the guide tube. 1. A method for building a three-dimensional object with an extrusion-based layered deposition system having a mount , the method comprising:providing a first consumable assembly to the extrusion-based layered deposition system, wherein the first consumable assembly comprises a container portion retaining a supply of a filament, an extruder portion, and a guide tube configured to guide the filament from the container portion to the extruder portion;placing the container portion at a location that is offset from the mount;inserting the extruder portion in the mount such that the guide tube extends between the location of the placed container portion and the inserted extruder portion;building at least a portion of the three-dimensional object from the filament retained in the container portion; andinterchanging the first consumable assembly with a second consumable assembly.2. The method of claim 1 , wherein the building step comprises:feeding successive portions of the filament from the container portion, through the guide tube, and to the extruder portion;melting the successively fed portions of the filament in the extruder portion to form an extrudable material; andextruding the extrudable material from the extruder portion.3. The method of claim 1 , and further comprising creating an electrical connection between the inserted extruder portion and the extrusion-based layered deposition system.4. The method of claim 1 , wherein the second consumable assembly comprises a second container portion claim 1 , a second guide tube claim 1 , and a second extruder portion claim 1 , and wherein interchanging the first consumable assembly with the second consumable assembly comprises:removing the extruder portion and the guide tube of the first consumable assembly from the extrusion- ...

LAYER TRANSFUSION FOR ADDITIVE MANUFACTURING

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part. 1. An additive manufacturing system for printing a three-dimensional part , the additive manufacturing system comprising:an imaging engine configured to develop an imaged layer of a thermoplastic-based powder;a movable build platform;a transfer medium configured to receive the imaged layer from the imaging engine, and to convey the received imaged layer;a first heater configured to heat the imaged layer on the transfer medium;a transfusion element configured to transfer the heated imaged layer conveyed by the transfer medium onto the movable build platform by pressing the heated imaged layer between the transfer medium and the moveable build platform; anda cooling unit configured to actively cool the transferred layer.2. The additive manufacturing system of claim 1 , wherein the transfusion element is configured to press the heated imaged layer between the transfer medium and the moveable build platform a duration that is at least an average time for polymer molecules of the heated imaged layer to diffuse one molecular radius of gyration.3. The additive manufacturing system of claim 1 , and further comprising a second heater configured to pre-heat at least a portion of the thermoplastic part being printed on the moveable build platform.4. The additive manufacturing system of claim 1 , and further comprising a second heater configured to post-heat the transferred layer.5. The additive manufacturing system of claim 1 , wherein the transfusion element comprises a nip roller.6. The additive manufacturing system of claim 1 , wherein the transfer medium comprises a rotatable belt.7. The additive ...

LAYER TRANSFUSION WITH HEAT CAPACITOR BELT FOR ADDITIVE MANUFACTURING

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.

ADDITIVE MANUFACTURING METHOD FOR BUILDING THREE-DIMENSIONAL OBJECTS WITH CORE-SHELL ARRANGEMENTS, AND THREE-DIMENSIONAL OBJECTS THEREOF

A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament. 1. A three-dimensional object built with an extrusion-based additive manufacturing system , the three-dimensional object comprising:a plurality of solidified layers each comprising roads formed from a flowable consumable material that exits an extrusion tip of the extrusion-based additive manufacturing system, wherein the flowable consumable material exiting the extrusion tip comprises a core material and a shell material that is compositionally different from the core material, and wherein the shell material at least partially encases the core material to provide an interface between the core material and the shell material; andwherein at least a portion of the roads of the plurality of solidified layers comprise core regions of the core material and shell regions of the shell material, and wherein the core regions and the shell regions substantially retain cross-sectional profiles corresponding to the interface between the core material and the shell material of the flowable consumable material.2. The three-dimensional object of claim 1 , wherein the core material and the shell material at least partially interdiffuse at the interface between the core material and the shell material.3. The three-dimensional object of claim 1 , wherein the core material comprises a thermoplastic polymer.4. The three-dimensional object of claim 3 , wherein the shell material comprises a ...

RIBBON LIQUEFIER AND METHOD OF USE IN EXTRUSION-BASED DIGITAL MANUFACTURING SYSTEMS

A ribbon liquefier comprising an outer liquefier portion configured to receive thermal energy from a heat transfer component, and a channel at least partially defined by the outer liquefier portion, where the channel has dimensions that are configured to receive the ribbon filament, and where the ribbon liquefier is configured to melt the ribbon filament received in the channel to at least an extrudable state with the received thermal energy to provide a melt flow. The dimensions of the channel are further configured to conform the melt flow from an axially-asymmetric flow to a substantially axially-symmetric flow in an extrusion tip connected to the ribbon liquefier. 1. A method for building a three-dimensional model in an extrusion-based digital manufacturing system , the method comprising:heating a ribbon liquefier retained by the extrusion-based digital manufacturing system, the ribbon liquefier having a static channel with an inlet end and an outlet end;feeding a ribbon filament into the inlet end of the static channel of the heated ribbon liquefier;melting the ribbon filament in the static channel to at least an extrudable state with the heat to provide a molten material, wherein the molten material conforms to an axially-asymmetric flow in the channel;moving the molten material having the axially-asymmetric flow from the static channel to an extrusion tip disposed at the outlet end of the channel with a viscosity-pump action of the fed ribbon filament;conforming the molten material to a substantially axially-symmetric flow;extruding the molten material having the substantially axially-symmetric flow from the extrusion tip; anddepositing the extruded material as a road to form at least a portion of a layer of the three-dimensional model.2. The method of claim 1 , wherein the static channel extends along a longitudinal axis and has a substantially-rectangular cross section perpendicular to the longitudinal axis claim 1 , wherein the substantially-rectangular ...

LIQUEFIER ASSEMBLY HAVING INLET LINER FOR USE IN ADDITIVE MANUFACTURING SYSTEM

A liquefier assembly for use in an additive manufacturing system, the liquefier assembly comprising a liquefier tube, a rigid sleeve secured to an inlet end of the liquefier tube, an extrusion tip secured to an outlet end of the liquefier tube, and a hollow liner disposed at least partially within the rigid sleeve such that inner surfaces of the liquefier tube and the hollow liner are substantially flush, and where the inner surface of the hollow liner has a low surface energy. 1. A liquefier assembly for use in an additive manufacturing system , the liquefier assembly comprising:a liquefier tube compositionally comprising a metallic material, and having an inlet end and an outlet end offset along a longitudinal axis, wherein the liquefier tube further includes a liquefier inner surface having a first average inner cross-sectional area;a rigid sleeve having a first end and a second end offset along the longitudinal axis, wherein the second end of the rigid sleeve is secured to the inlet end of the liquefier tube, and wherein the rigid sleeve further includes a sleeve inner surface having a second average inner cross-sectional area that is greater than the first average inner cross-sectional area of the liquefier inner surface;a hollow liner disposed at least partially within the rigid sleeve against the sleeve inner surface, wherein the hollow liner has a liner inner surface and an average wall thickness, the average wall thickness being substantially the same as a difference between the second average inner cross-sectional area of the rigid sleeve inner surface and the first average inner cross-sectional area of the liquefier inner surface such that the liner inner surface is substantially flush with the liquefier inner surface, and wherein the liner inner surface has a coefficient of friction of less than about 0.3; andan extrusion tip secured to the outlet end of the liquefier tube.2. The liquefier assembly of claim 1 , wherein the hollow liner compositionally ...

AUTOMATED CALIBRATION METHOD FOR ADDITIVE MANUFACTURING SYSTEM, AND METHOD OF USE THEREOF

A method for calibrating a print head for use in an additive manufacturing system, the method comprising positioning the print head over a calibration target, where the calibration target has a top surface with a plurality of edges. The method further comprising moving a tip of the print head to identify coordinate locations of the edges, and setting a calibration parameter for the print head. 1. A method for calibrating a print head for use in an additive manufacturing system , the method comprising:positioning the print head at over a calibration target retained by a moveable platen of the additive manufacturing system, wherein the calibration target has a top surface with a plurality of edges;moving a tip of the print head along the top surface in a first direction until the tip drops off of a first edge of the plurality of edges;identifying a first coordinate location at the first edge where the tip dropped;moving the tip along the top surface in a second direction that is substantially perpendicular to the first direction until the tip drops off of a second edge of the plurality of edges;identifying a second coordinate location at the second edge where the tip dropped;determining a coordinate point of the calibration target based at least in part on the first coordinate location and the second coordinate location; andsetting a calibration parameter for the print head in a horizontal plane based on the determined coordinate point.2. The method of claim 1 , and further comprising:lowering the tip of the print head toward the top surface of the calibration target;identifying a coordinate point along a vertical axis at which the lowered tip contacts the top surface; andsetting a calibration parameter for the print head along the vertical axis based on the identified coordinate point.3. The method of claim 1 , and further comprising:moving the tip along the top surface in a third direction that is substantially opposite of the first direction until the tip drops off ...

Support Structure Removal System

A support structure removal system comprising a vessel and a second component. The vessel comprises a vessel body, a porous floor configured to retain a three-dimensional part, and an impeller rotatably mounted below the porous floor. The second component comprises a surface configured to operably receive the vessel, and a rotation-inducing assembly located below the surface, where the rotation-inducing assembly is configured to rotate the impeller with magnetic fields when the vessel is received on the surface of the second component to agitate and direct flows of an aqueous fluid through the porous floor.

HOPPER VALVE FOR EXTRUSION-BASED ADDITIVE MANUFACTURING SYSTEMS, AND METHODS OF USE THEREOF

A hopper valve for transferring particles from a supply container to a hopper, the hopper valve comprising a valve body coupled to the supply container, a fill tube moveably coupled to the valve body, and a foot member moveably coupled to the fill tube and configured to engage the hopper. 1. A hopper valve for transferring particles from a supply container to a hopper , the hopper valve comprising:a valve body configured to couple to the supply container and having at least one fill port;a fill tube moveably coupled to the valve body and having at least one slot;a first biasing component configured to bias the fill tube in a first direction relative to the valve body, wherein the at least one slot is configured to align with the at least one fill port when the fill tube is moved against the bias of the first biasing component;a foot member moveably coupled to the fill tube and configured to engage the hopper; anda second biasing component configured to bias the foot member in the first direction relative to the valve body.2. The hopper valve of claim 1 , wherein the fill tube comprises:a head component moveably retained within a central channel of the valve body; and an outlet end opposite of the head component; and', 'an inner conduit extending between the head component an outlet end, wherein the at least one slot extends through the tube component to the inner conduit., 'a tube component extending from the head component, and further comprising3. The hopper valve of claim 2 , wherein the head component of the fill tube and the valve body comprise reciprocating shoulders to moveably retain the head component in the central channel of the valve body.4. The hopper valve of claim 2 , wherein the fill tube further comprises:a first hard stop retained adjacent to the outlet end; anda second hard stop retained between the head component and the outlet end, wherein the first hard stop and the second hard stop define a range of movement for the foot member relative to the ...

PRINT HEAD NOZZLE FOR USE WITH ADDITIVE MANUFACTURING SYSTEM

A nozzle for printing three-dimensional parts with an additive manufacturing system, the nozzle comprising a nozzle body having an inlet end and a tip end offset longitudinally from the inlet end, a tip pipe for extruding a flowable material, an inner ring extending circumferentially around the tip pipe at the outlet end, an outer ring extending circumferentially around the inner ring, at least one annular recessed groove located circumferentially between the inner ring and the outer ring. 1. A nozzle for use with a print head in an extrusion-based additive manufacturing system , the nozzle comprising:an inlet end configured to be secured to a flow channel of the print head;a tip end offset longitudinally from the inlet end;a tip pipe extending longitudinally at least part way between the inlet end to the tip end; andan inner ring located at the tip end, the inner ring having an inner diameter at the tip pipe;an outer ring located at the tip end, and extending around the inner ring; andat least one annular recessed groove located at the tip end, and circumferentially between the inner ring and the outer ring.2. The nozzle of claim 1 , wherein the inner ring also has an outer diameter defining an inner diameter of the at least one recessed groove claim 1 , and a planar bottom surface extending between the inner diameter and the outer diameter.3. The nozzle of claim 1 , wherein the outer diameter of the inner ring ranges from about 500 micrometers to about 1 claim 1 ,300 micrometers.4. The nozzle of claim 1 , wherein the outer ring comprises a knife-edge face.5. The nozzle of claim 4 , wherein the outer ring has a knife-edge diameter ranging from about 1 claim 4 ,500 micrometers to about 2 claim 4 ,500 micrometers.6. The nozzle of claim 1 , wherein the at least one recessed groove comprises two recessed grooves claim 1 , and wherein the nozzle further comprises an intermediate ring located at the tip end between the two recessed grooves.7. The nozzle of claim 1 , ...

DRAW CONTROL FOR EXTRUSION-BASED ADDITIVE MANUFACTURING SYSTEMS

A method for improving part quality for a printed three-dimensional part, the method comprising moving a print head nozzle along a substantially linear segment of a tool path at a tip height above a previous layer of the three-dimensional part while extruding a flowable material, and producing an extruded road from the extruded flowable material having a road height above the previous layer, where the tip height is greater than the road height due at least in part to draw on the extruded road. 1. A method for improving part quality for a printed three-dimensional part , the method comprising:providing a print head retained by an extrusion-based additive manufacturing system, the print head comprising a nozzle; andmoving the nozzle along a substantially linear segment of a tool path at a tip height above a previous layer of the three-dimensional part while extruding a flowable material;producing an extruded road from the extruded flowable material having a road height above the previous layer, and wherein the tip height ranges from about 150% to about 250% of the road height due at least in part to draw on the extruded road, wherein the printed three-dimensional part is substantially free of surface cresting.2. The method of claim 1 , wherein the tip height ranges from about 175% to about 225% of the road height.3. The method of claim 1 , wherein the tool path comprises a corner vertex claim 1 , and where the method further comprises:lowering the moving nozzle down from the tip height such that, upon reaching the corner vertex, the moving nozzle is at a height ranging from about 90% to about 120% of the road height; andraising the moving nozzle up to the tip height after passing the corner vertex.4. The method of claim 3 , wherein the flowable material is extruded from the moving nozzle at a substantially constant volumetric flow rate as the moving nozzle passes the corner vertex.5. The method of claim 1 , wherein the tool path comprises a start vertex claim 1 , and ...

ADDITIVE MANUFACTURING TECHNIQUE FOR PRINTING THREE-DIMENSIONAL PARTS WITH PRINTED RECEIVING SURFACES

A method for printing three-dimensional parts with an additive manufacturing system, comprising printing successive layers having increasing cross-sectional areas, and printing layers of a three-dimensional part onto the previously printed layers, where a last layer of the previously printed successive layers has a cross-sectional area that is at least as large as a footprint area of the three-dimensional part. 1. A method for printing three-dimensional parts with an additive manufacturing system , the method comprising:printing successive layers along a printing axis onto a first receiving surface of a print foundation, wherein the printed successive layers have increasing cross-sectional areas parallel to a build plane that is normal to the printing axis, wherein a last layer of the printed successive layers defines a second receiving surface; andprinting layers of a three-dimensional part onto the second receiving surface, wherein the last layer of the printed successive layers has a first cross-sectional area parallel to the build plane, wherein a first layer defines of the three-dimensional part has a second cross-sectional area parallel to the build plane, and wherein the first cross-sectional area is at least as large as the second cross-sectional area.2. The method of claim 1 , wherein the printed successive layers define a soluble support structure.3. The method of claim 1 , and further comprising printing layers of a scaffold for the three-dimensional object onto the second receiving surface claim 1 , wherein a first layer of the scaffold has a third cross-sectional area parallel to the build plane claim 1 , and wherein the first cross-sectional area is at least as large as a combination of the second cross-sectional area and the third cross-sectional area.4. The method of claim 3 , wherein a last layer of the scaffold defines a third receiving surface claim 3 , and wherein the method further comprises printing successive layers along the printing axis ...

ADDITIVE MANUFACTURING SYSTEM WITH EXTENDED PRINTING VOLUME, AND METHODS OF USE THEREOF

An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region. 1. An additive manufacturing system for printing three-dimensional parts , the system comprising:a heating mechanism configured to heat a region of the system to one or more temperatures;a print head configured to print a part material along a non-vertical printing axis;a non-horizontal receiving surface configured to receive the printed part material from the print head in the heated region to produce the three-dimensional part in a layer-by-layer manner; anda drive mechanism configured to index the receiving surface along the non-vertical printing axis such that the receiving surface and at least a portion of the three-dimensional part move out of the heated region.2. The system of claim 1 , wherein the region of the system comprises a chamber of the system having chamber walls and a lateral port claim 1 , and wherein the indexing moves the receiving surface and at least a portion of the three-dimensional part through the lateral port.3. The system of claim 1 , wherein the non-vertical printing axis comprises a substantially horizontal printing axis claim 1 , and wherein the non-horizontal receiving surface comprises a substantially vertical receiving surface.4. The system of claim 1 , wherein the receiving surface is a surface of a platen of the system claim 1 , and wherein the drive mechanism comprises a platen gantry that having a first end disposed within the region that is heated and a second end disposed outside of the region that is heated.5. The system of claim 4 , wherein the platen gantry ...

METHOD FOR PRINTING THREE-DIMENSIONAL PARTS WITH ADDITIVE MANUFACTURING SYSTEMS USING SCAFFOLDS

A method for printing a three-dimensional part with an additive manufacturing system, comprising printing the three-dimensional part in a layer-by-layer manner along a printing axis in the additive manufacturing system, printing a scaffold in a layer by layer manner along the printing axis along with the printing of the three-dimensional part, and bracing the three-dimensional part laterally relative to the printing axis with the scaffold while printing the three-dimensional part. 1. A method for printing a three-dimensional part with an additive manufacturing system , the method comprising:printing the three-dimensional part in a layer-by-layer manner along a printing axis in the additive manufacturing system;printing a scaffold in a layer by layer manner along the printing axis along with the printing of the three-dimensional part; andbracing the three-dimensional part laterally relative to the printing axis with the scaffold while printing the three-dimensional part.2. The method of claim 1 , wherein the scaffold comprises a ribbon portion having a wave pattern that is connected to the three-dimensional part at one or more tangential locations of the ribbon portion.3. The method of claim 2 , wherein the printed scaffold further comprises a substantially planar conveyor base connected to the ribbon portion opposite of the three-dimensional part.4. The method of claim 1 , wherein the scaffold has one or more walls that are each about one road-width thick.5. The method of claim 1 , wherein the three-dimensional part and the scaffold are printed onto a print foundation retained by the additive manufacturing system claim 1 , and wherein the method further comprises indexing the print foundation along the printing axis.6. The method of claim 5 , and further comprising:engaging the print foundation with a drive mechanism of the additive manufacturing system, wherein indexing the print foundation is performed by the drive mechanism; andengaging the scaffold with the ...

Method for building and using three-dimensional objects containing embedded identification-tag inserts

A method for building a three-dimensional object containing an identification-tag insert, the method comprising performing a build operation to form layers of the three-dimensional object using a layer-based additive technique, placing the identification-tag insert on at least a portion of the layers during the build operation, and reading information from the identification-tag insert.

Electrophotography-based additive manufacturing system with reciprocating operation

An additive manufacturing system for printing a three-dimensional part using electrophotography, the additive manufacturing system comprising a rotatable photoconductor component, first and second development stations configured to develop layers of materials on a surface of the rotatable photoconductor component while the rotatable photoconductor component rotates in opposing rotational directions, and a platen configured to operably receive the developed layers in a layer-by-layer manner to print the three-dimensional part from at least a portion of the received layers.

CERAMIC SUPPORT STRUCTURE

A pre-ceramic support structure for additive manufacturing, that upon thermal processing, is soluble in various solvents. 115-. (canceled)16. A feedstock material for use in an additive manufacturing system , the feedstock material comprising:a pre-ceramic material in powder form;a thermoplastic binder; andwherein upon thermal processing of the feedstock, the pre-ceramic material is removable in a solvent.171. The feedstock material of claim , wherein the thermoplastic binder is a polymeric matrix comprising one or more of polyolefins , polylactic acid polymers , and acrylonitrile butadiene styrene polymers or combinations thereof.181. The feedstock material of claim , wherein the pre-ceramic material comprises calcium carbonate , sodium carbonate , sodium aluminate or combinations thereof.191. The feedstock of claim , wherein the solvent comprises water , carbonated solutions , acidic solutions and combinations thereof.201. The feedstock material of claim , and further comprising one or more of a fluxing materials , a polymer processing additive or combinations thereof.215. The feedstock material of claim , wherein the fluxing material comprises glass frits having boron trioxide , silicon oxide , zirconium dioxide , lithium oxide , fluorine , titanium dioxide , and combinations thereof.221. The feedstock of claim , wherein the feedstock material is a filament produced by melt-processing and is suitable for building a support structure for a three dimensional ceramic article.237. The feedstock of claim , wherein the feedstock material is a thermoplastic filament of pre-ceramic powder configured for building the support structure at temperatures of about 160° C.-200° C. and at a speed between about 20 mm/sec and 100 mm/sec.24. A method of printing a three-dimensional ceramifiable article with an additive manufacturing system , the method comprising:printing at least one build layer with the additive manufacturing system, wherein the build layer is pre-sintered; a pre ...

Feedstock and methods for additive manufacturing of radiation shielding parts

A melt-processable consumable material configured as a feedstock for use in an additive manufacturing system includes a polymeric matrix comprising one or more polyaryletherketones, wherein the polymeric matrix comprises between about 10 wt % and about 50 wt % of the total weight of the feedstock. The material includes radiation shielding particles dispersed within the polymer matrix wherein the radiation shielding particles comprise between about 50 wt % and less than 90 wt % of the total weight of the feedstock.

Polyglycolic acid support material for additive manufacturing systems

A support material for use in an additive manufacturing system, which compositionally includes a polyglycolic acid polymer, which is at least partially soluble in an aqueous solution, and which is configured for use in the additive manufacturing system for printing a support structure in coordination with printing of a three-dimensional part.

Recycling and reuse of sulfonated polymer material in additive manufacturing

A method of recycling and reusing a tap water-soluble sulfonated polymer material from a structural component made using an additive manufacturing process comprises dissolving the structural component in water to disperse the sulfonated polymer material into the water. The sulfonated polymer material is precipitated from the water and recovered; then dried and reformed into a form suitable for subsequent use as a consumable feedstock in a subsequent additive manufacturing process.

PRINT HEAD ASSEMBLY AND PRINT HEAD FOR USE IN FUSED DEPOSITION MODELING SYSTEM

A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly. 1. A print head assembly for use in an additive manufacturing system , the print head assembly comprising:a carriage frame configured to be retained by a gantry mechanism of the additive manufacturing system to move the carriage frame substantially in a plane;a control board retained by the carriage frame;a voice coil mechanism configured to receive electrical power from the control board to controllably move a received replaceable print head relative to the carriage in directions outside of the plane; and restrict movement of the received print head relative to the carriage frame in directions parallel to the plane; and', 'permit the voice coil mechanism to controllably move the received print head relative to the carriage frame in the directions outside of the plane; and, 'at least one suspension mechanism that is secured to the carriage frame, and configured toa sensor assembly configured to operably measure positions of the received print head relative to the carriage frame in the directions outside of the plane, and to send information of the measured positions to the control board.2. The print head assembly of claim 1 , wherein the sensor assembly comprises an optical encoder assembly.3. The print head assembly of claim 1 , wherein the at least one suspension mechanism is further configured to prevent roll claim 1 , pitch claim 1 , and yaw movements of the received print head relative to the carriage frame in the plane.4. The print head assembly of claim 1 , wherein the carriage frame is further configured to operably receive a second print head claim 1 , and wherein the print head assembly further comprises:a second voice coil mechanism configured to receive ...

LIQUEFIER ASSEMBLY FOR USE IN EXTRUSION-BASED ADDITIVE MANUFACTURING SYSTEMS

A liquefier assembly for use in an extrusion-based additive manufacturing system, the liquefier assembly comprising a downstream portion having a first average inner cross-sectional area, and an upstream having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion defining a shoulder configured to restrict movement of a melt meniscus of a consumable material. 1. A liquefier assembly for use in an extrusion-based additive manufacturing system , the liquefier assembly comprising: an upstream portion configured to receive a consumable material, wherein the upstream portion has an upstream inner surface compositionally comprising a fluorinated polymer, and wherein the upstream inner surface has an upstream average inner cross-sectional area; and', 'a downstream portion configured to receive the consumable material from the upstream portion, wherein the downstream portion has a downstream inner surface compositionally comprising a metallic material, and wherein the downstream inner surface has a downstream average inner cross-sectional area that is greater than the upstream average inner cross-sectional area; and', 'a shoulder located at an intersection of the upstream portion and the downstream portion that is configured to restrict movement of a melt meniscus of the consumable material;, 'a liquefier comprisingan external heater configured to conduct heat to the received consumable material in the downstream portion; andan extrusion tip coupled to the downstream portion.2. The liquefier assembly of claim 1 , wherein the fluorinated polymer for the inner surface of the upstream portion comprises polytetrafluoroethylene.3. The liquefier assembly of claim 1 , wherein the downstream average inner cross-sectional area is at least 105% of the upstream average inner cross-sectional area.4. The liquefier assembly of claim 3 , wherein the downstream average inner cross-sectional area ranges from about 110% of ...

Heated air system for 3D printer

An apparatus and a method using the apparatus provides heated air in an additive manufacturing process for building a three-dimensional part. The method comprises providing a stream of flowable part material at an initial build level, the initial build level being positioned in and defining a horizontal plane wherein the stream of flowable material is being initially disposed on previously deposited part material. Heated air is provided at a selected temperature corresponding to the temperature of the stream of flowable part material such that the stream of flowable part material deposits on previously deposited part material in an adhering fashion thereby forming the three-dimensional part where in the heated air is provided in the horizontal plane of the initial build level.

Lever tray release

A platen assembly for use in a 3D printer includes a frame and a platen supported by the frame. The platen is configured to receive a removable build tray. A lever release mechanism of the platen assembly is coupled to the frame and is configured to both secure the build tray to the platen for printing of the part, and to eject the build tray from the platen after printing of the part.

Semi-crystalline build materials

A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having an enthalpy that is between about 2 J/g heat of fusion and about 80% of the heat of fusion of the neat semi-crystalline material, as measured by differential scanning calorimetry (DSC) when cooling from a melting temperature to a hot crystalline temperature at a rate of 10° C./min.

ENCODED CONSUMABLE MATERIALS AND SENSOR ASSEMBLIES FOR USE IN ADDITIVE MANUFACTURING SYSTEMS

A consumable material and sensor assembly for use in an additive manufacturing system, the consumable material comprising an exterior surface having encoded markings that are configured to be read by the sensor assembly, where the consumable material is configured to be consumed in the additive manufacturing system to build at least a portion of a three-dimensional model. 1. An encoded filament for use in an additive manufacturing system having an extrusion head , the encoded filament comprising:compositionally, a consumable material;a longitudinal length;volume-increment markings that are offset from each other along the longitudinal length of the encoded filament by increment lengths that vary to define segments of the encoded filament having volumes that are substantially the same, wherein the volume-increment markings are configured to be read by an optical sensor of the additive manufacturing system; anda cross-sectional geometry configured to be received by a liquefier of the extrusion head for building a three-dimensional model from the consumable material.2. The encoded filament of claim 1 , wherein the cross-sectional geometry comprises a substantially circular geometry having an average diameter ranging from about 0.8 millimeters to about 2.5 millimeters.3. The encoded filament of claim 1 , wherein the cross-sectional geometry has a width and thickness claim 1 , wherein the width of the cross-sectional geometry ranges from about 1.0 millimeter to about 10.2 millimeters claim 1 , and wherein the thickness of the cross-sectional geometry ranges from about 0.08 millimeters to about 1.5 millimeters.4. The encoded filament of claim 1 , wherein the volume-increment markings extend substantially along an entirety of the longitudinal length.5. The encoded filament of claim 1 , wherein the consumable material comprises a thermoplastic material claim 1 , and wherein the volume-increment markings comprise an ultraviolet-activated material.6. The encoded filament of ...

3d printer with coupling for attaching print head and additional equipment to head carriage

A 3D printer includes a gantry configured to move in a plane substantially parallel to a build plane. The system includes a platen configured to support a part being built in a layer by layer process, wherein the platen is configured to move in a direction substantially normal to the build plane. The system includes a head carriage carried by the gantry wherein the head carriage includes a first support member carrying a first retaining mechanism and a second support member carrying a second retailing mechanism. The first and second retaining mechanisms are both configured to receive and retain the print head or the additional equipment wherein both the removable print head and the removable additional equipment have substantially a same interface with the head carriage. Non-limiting examples of addition equipment includes a blower configured to discharge a stream of heating or cooling gas, a light, a sensor, a laser, a contact chiller, a roller, a cutting instrument, a bead shaping instrument, a dispenser, a bead blaster, a camera and/or a vacuum.

ADDITIVE MANUFACTURING WITH POLYAMIDE CONSUMABLE MATERIALS

A consumable material for use in an additive manufacturing system, the consumable filament comprising a polyamide blend of at least one semi-crystalline polyamide, and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, and a physical geometry configured to be received by the additive manufacturing system for printing a three-dimensional part from the consumable material in a layer-by-layer manner using an additive manufacturing technique. The consumable material is preferably capable of printing three-dimensional parts having good part strengths and ductilities, and low curl. 1. A method for printing a three-dimensional part with an additive manufacturing system , the method comprising:providing a consumable material comprising a polyamide blend having at least one semi-crystalline polyamide and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, wherein the consumable material has a solidification temperature and a glass transition temperature, and wherein the consumable material is capable of printing a three-dimensional part having a curl less than about 0.01 inches pursuant to a Curl Bar Test, and has a relative strength in a conditioned state of at least about 1,600 psi;heating a chamber of the additive manufacturing system or locally heating a deposition region of the additive manufacturing system to a temperature between the solidification temperature and the glass transition temperature of the consumable material;feeding the consumable material to a liquefier assembly retained by the additive manufacturing system;melting the consumable material in the liquefier assembly; andextruding the molten consumable material from the liquefier assembly as a series of roads in the heated chamber or the locally-heated deposition region to print the three-dimensional part in a layer-by-layer manner.2. The method of claim 1 , wherein the at least one ...

Additive Manufacturing with Polyamide Consumable Materials

A consumable material for use in an additive manufacturing system, the consumable filament comprising a polyamide blend of at least one semi-crystalline polyamide, and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, and a physical geometry configured to be received by the additive manufacturing system for printing a three-dimensional part from the consumable material in a layer-by-layer manner using an additive manufacturing technique. The consumable material is preferably capable of printing three-dimensional parts having good part strengths and ductilities, and low curl. 1. A method for printing a three-dimensional part with an additive manufacturing system , the method comprising:providing a consumable material comprising a polyamide blend having at least one semi-crystalline polyamide and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, wherein the consumable material has a solidification temperature and a glass transition temperature, and wherein the consumable material is capable of printing a three-dimensional part having a curl less than about 0.01 inches pursuant to a Curl Bar Test, and has a relative strength in a conditioned state of at least about 1,600 psi;heating a chamber of the additive manufacturing system or locally heating a deposition region of the additive manufacturing system to a temperature between the solidification temperature and the glass transition temperature of the consumable material;feeding the consumable material to a liquefier assembly retained by the additive manufacturing system;melting the consumable material in the liquefier assembly; andextruding the molten consumable material from the liquefier assembly as a series of roads in the heated chamber or the locally-heated deposition region to print the three-dimensional part in a layer-by-layer manner.2. The method of claim 1 , wherein the at least one ...

Additive Manufacturing System and Process with Precision Substractive Technique

An additive manufacturing system and process for producing three-dimensional parts, which includes forming layers of the three-dimensional part from a part material at a first resolution, and ablating selected voxels of the formed layers with a laser beam at a second resolution that is higher than the first resolution. 1. An additive manufacturing system for producing three-dimensional parts , the system comprising:a platen;a moveable head configured to form layers of the three-dimensional part from a part material at a first resolution onto the platen;a radiation-emitting device configured to emit high-peak-power synergistic radiation;a masking unit configured to spatially modulate the emitted radiation towards the formed layers of the three-dimensional part to ablate selected voxels of the formed layers at a second resolution that is higher than the first resolution; andat least one controller configured to manage operations of the moveable head and the laser device.2. The system of claim 1 , wherein the radiation-emitting device comprises an excimer laser device.3. The system of claim 1 , wherein the moveable head comprises a print head that is configured to print the layers of the three-dimensional part by depositing the part material.4. The system of claim 1 , and further comprising a scanner configured to scan the printed layers.5. The system of claim 4 , wherein the scanner is incorporated into the radiation-emitting device.6. The system of claim 1 , wherein the additive manufacturing system comprises a housing claim 1 , and wherein the radiation-emitting device is configured to reside outside of the housing.7. The system of claim 1 , wherein the radiation-emitting device is configured to emit the laser beam pulses with an average power density ranging from about 0.01 J/cm claim 1 , and about 10 J/cm.8. The system of claim 1 , wherein the controller is further configured to adjust the spatial modulation of the masking unit.9. An additive manufacturing farm ...

COIL ASSEMBLY HAVING PERMEABLE HUB

A coil assembly comprising a coil of a strand-based material retained in a figure-8 configuration, and having an inner layer and an outer layer, where the inner layer of the coil defines a core region of the coil, and where the coil is configured to unwind loop by loop beginning from the inner layer and moving towards the outer layer as the strand-based material is drawn through a payout hole. The coil assembly also comprises a permeable hub configured to reduce payout entanglement of the strand-based material. 1. A coil assembly comprising:a coil of a strand-based material retained in a figure-8 configuration, and having a payout hole for dispensing successive segments of the strand-based material, the payout hole extending from an inner layer of the coil to an outer layer of the coil, wherein the inner layer of the coil defines a core region of the coil, and wherein the coil is configured to unwind loop by loop beginning from the inner layer and moving towards the outer layer as the strand-based material is drawn through the payout hole; anda permeable hub retained in the core region of the coil, the permeable hub being displaceable by the unwinding of the strand-based material, and configured to prevent the strand-based material from forming more than one loop at a time in the core region as the strand-based material is pulled through the payout hole.2. The coil assembly of claim 1 , wherein the permeable hub comprises a plurality of displaceable bodies retained in the core region.3. The coil assembly of claim 2 , wherein the plurality of displaceable bodies comprise spheroids having a size distribution of at least two different average diameters.4. The coil assembly of claim 2 , wherein at least a portion of the plurality of displaceable bodies comprise are configured to retain desiccant.5. The coil assembly of claim 1 , wherein the permeable hub comprises at least two biasing bodies retained in the core region.6. The coil assembly of claim 1 , and further ...

LIQUEFIER ASSEMBLY FOR USE IN ADDITIVE MANUFACTURING SYSTEM

A liquefier assembly for use in an additive manufacturing system, where the liquefier assembly includes a liquefier tube, a nozzle secured to an outlet end of the liquefier tube, a heating element extending at least partially around the liquefier tube to generate a hot zone in the liquefier tube, a hollow spacer disposed in the channel; and a hollow liner disposed in the channel abutting against an upstream shoulder of the hollow spacer. 1. A liquefier assembly for use in an additive manufacturing system , the liquefier assembly comprising:a liquefier tube compositionally comprising a first metallic material, and having an inlet end and outlet end offset along a longitudinal axis, and a channel extending between the inlet end and the outlet end;a nozzle secured to the outlet end of the liquefier tube;a heating element extending at least partially around the liquefier tube, wherein the heating element is configured to generate a hot zone in the liquefier tube;at least one hollow spacer compositionally comprising a second metallic material, the at least one hollow spacer being disposed in the channel and having a first end adjacent to the nozzle and a second end that defines a shoulder that is upstream along the longitudinal axis from the hot zone when generated by the heating element; anda hollow liner compositionally comprising a fluoropolymer, the hollow liner being disposed in the channel and having a first end abutting against the shoulder of the at least one hollow spacer.2. The liquefier assembly of claim 1 , wherein the fluoropolymer of the hollow liner comprises polytetrafluoroethylene.3. The liquefier assembly of claim 1 , wherein the hollow liner further compositionally comprises from about 0.1% to about 30% of one or more fillers.4. The liquefier assembly of claim 1 , wherein the first metallic material of the liquefier tube and the second metallic material of the at least one hollow spacer each comprise stainless steel.5. The liquefier assembly of claim 1 ...

LIQUEFIER ASSEMBLY FOR ADDITIVE MANUFACTURING SYSTEMS, AND METHODS OF USE THEREOF

A liquefier assembly for use in an additive manufacturing system, which includes a rigid member having a gap, a liquefier tube operably disposed in the gap, one or more heater assemblies disposed in the gap in contact with the liquefier tube, and configured to heat the liquefier tube in a zone-by-zone manner, preferably one or more thermal resistors disposed in the gap between the rigid member and the heater assemblies, and preferably one or more sensors configured to operably measure pressure within the liquefier tube. The one or more heater assemblies may be operated to provide dynamic heat flow control. 1. A liquefier assembly for use in an additive manufacturing system , the liquefier assembly comprising:a rigid member comprising one or more thermally-conductive materials, and having a gap extending along a longitudinal axis;a liquefier tube disposed within the gap, and having an inlet end and an outlet end offset along the longitudinal axis;a heater assembly disposed in the gap and in contact with the liquefier tube, wherein the heater assembly is configured to heat the liquefier tube in a zone-by-zone manner along the longitudinal axis;a thermal resistor disposed in the gap between the rigid member and the heater assembly, wherein the thermal resistor is configured to conduct a portion of the heat from the heater assembly to the rigid member; anda heat sink unit coupled to the rigid member to draw the conducted heat away from the rigid member.2. The liquefier assembly of claim 1 , wherein the rigid member comprises a clam block having a base portion connected to a pair of arms claim 1 , which collectively define the gap.3. The liquefier assembly of claim 2 , wherein a portion of the heat sink unit extends through the base portion of the rigid member.4. The liquefier assembly of claim 1 , wherein the liquefier tube comprises a ribbon liquefier tube.5. The liquefier assembly of claim 1 , wherein the liquefier tube comprises a cylindrical liquefier tube.6. The ...

LIQUEFIER ASSEMBLY WITH MULTIPLE-ZONE PLATE HEATER ASSEMBLY

A liquefier assembly for use in an additive manufacturing system, which includes a rigid member having a gap, a liquefier tube operably disposed in the gap, one or more heater assemblies disposed in the gap in contact with the liquefier tube, and configured to heat the liquefier tube in a zone-by-zone manner, preferably one or more thermal resistors disposed in the gap between the rigid member and the heater assemblies, and preferably one or more sensors configured to operably measure pressure within the liquefier tube. The one or more heater assemblies may be operated to provide dynamic heat flow control. 1. A liquefier assembly for use in an additive manufacturing system , the liquefier assembly comprising:a liquefier tube having an inlet end and an outlet end offset along the longitudinal axis; a plate portion;', 'a plurality of conductor traces disposed on the plate portion, and configured to operably receive electrical power from the additive manufacturing system with independently controlled wattage levels; and', 'a plurality of heating elements disposed on the plate portion, and each in contact with one or more of the conductor traces to receive the electrical power from the one or more conductor traces, wherein the independently controlled wattage levels cause the heating elements to independently heat different zones of the liquefier tube along the longitudinal axis., 'a plate heater assembly comprising2. The liquefier assembly of claim 1 , wherein the plurality of conductor traces include three to eleven conductor traces.3. The liquefier assembly of claim 1 , wherein the liquefier tube comprises a ribbon liquefier tube.4. The liquefier assembly of claim 1 , wherein the liquefier tube comprises a cylindrical liquefier tube.5. The liquefier assembly of claim 1 , wherein the heater assembly is configured to operably measure temperatures of the different zones based on electrical resistances of heating elements in each of the different zones.6. The liquefier ...

ADDITIVE MANUFACTURING PROCESS WITH DYNAMIC HEAT FLOW CONTROL

A liquefier assembly for use in an additive manufacturing system, which includes a rigid member having a gap, a liquefier tube operably disposed in the gap, one or more heater assemblies disposed in the gap in contact with the liquefier tube, and configured to heat the liquefier tube in a zone-by-zone manner, preferably one or more thermal resistors disposed in the gap between the rigid member and the heater assemblies, and preferably one or more sensors configured to operably measure pressure within the liquefier tube. The one or more heater assemblies may be operated to provide dynamic heat flow control. 1. A method for printing a three-dimensional part with an additive manufacturing system , the method comprising:feeding a consumable material to a liquefier tube retained by the additive manufacturing system at multiple feed rates;heating the liquefier tube over multiple heating zones to melt the consumable material received in the liquefier tube;dynamically adjusting the heating of the liquefier tube over the multiple heating zones based at least in part of the feed rates of the consumable material to the liquefier tube; andextruding the molten consumable material from a nozzle retained by the liquefier tube.2. The method of claim 1 , wherein heating the liquefier tube over the multiple heating zones comprises relaying electrical power over conductor traces of a plate heater assembly to heating elements of the plate heater assembly.3. The method of claim 2 , wherein dynamically adjusting the heating of the liquefier tube comprises adjusting the amount of electrical power relayed over at least a portion of the conductor traces to the heating elements.4. The method of claim 1 , and further comprising:measuring temperatures in each of the multiple heating zones; andregulating the temperatures in each of the multiple heating zones in a closed-loop manner.5. The method of claim 1 , wherein dynamically adjusting the heating of the liquefier tube over the multiple ...

ADDITIVE MANUFACTURING SYSTEM AND PROCESS WITH MATERIAL FLOW FEEDBACK CONTROL

A liquefier assembly for use in an additive manufacturing system, which includes a rigid member having a gap, a liquefier tube operably disposed in the gap, one or more heater assemblies disposed in the gap in contact with the liquefier tube, and configured to heat the liquefier tube in a zone-by-zone manner, preferably one or more thermal resistors disposed in the gap between the rigid member and the heater assemblies, and preferably one or more sensors configured to operably measure pressure within the liquefier tube. The one or more heater assemblies may be operated to provide dynamic heat flow control. 1. An additive manufacturing system for printing three-dimensional parts in a layer-by-layer manner , the system comprising:a drive mechanism retained by the system and configured to feed a consumable material;a liquefier tube retained by the system and configured to receive the fed consumable material;a heater assembly retained by the system and configured to heat the liquefier tube to melt the received consumable material;a nozzle retained by the liquefier tube and configured to extrude the molten consumable material as an extrudate;at least one sensor that is configured to operably measure pressure within the liquefier tube; anda controller assembly configured to adjust feed rates of the consumable material with the drive mechanism based on the measured pressure to control a material flow rate of the extrudate in a closed-loop manner.2. The system of claim 1 , wherein the at least one sensor comprises a strain gauge.3. The system of claim 1 , wherein the liquefier tube is configured to expand while melting and extruding the consumable material claim 1 , and wherein the strain gauge is configured to operably measure the pressure within the liquefier tube by operably measuring the expansion of the liquefier tube.4. The system of claim 1 , wherein the controller assembly is configured to control the material flow rate of the extrudate in the closed-loop manner to ...

AUTOMATED ADDITIVE MANUFACTURING SYSTEM FOR PRINTING THREE-DIMENSIONAL PARTS, PRINTING FARM THEREOF, AND METHOD OF USE THEREOF

An additive manufacturing system comprising a platen assembly configured to restrain and release a film, a head gantry configured to retain a print head for printing a three-dimensional part on the restrained film, and a removal assembly configured to draw the film having the printed three-dimensional part from the platen assembly and to cut the drawn film. 1. An additive manufacturing system comprising:a platen gantry; a platform portion configured to be operably retained by the platen gantry, and having a surface;', 'a retention bracket biased towards the platform portion and configured to engage the surface of the platform portion for restraining a film therebetween, and to disengage from the surface to release the film;, 'a platen assembly comprisinga head gantry configured to retain a print head for printing a three-dimensional part on the restrained film; anda removal assembly configured to draw the film having the printed three-dimensional part from the platen assembly.2. The additive manufacturing system of claim 1 , wherein the surface of the platform portion comprises at least one indentation configured to draw a vacuum across the surface.3. The additive manufacturing system of claim 1 , and further comprising a support shaft configured to retain a supply of the film claim 1 , wherein the support shaft is separate from the platen assembly.4. The additive manufacturing system of claim 1 , wherein the platen assembly further comprises a wheel claim 1 , wherein the removal assembly comprises a drive roller claim 1 , and wherein the wheel and the drive roller are configured to nip the film therebetween when the platen assembly engages the removal assembly.5. The additive manufacturing system of claim 1 , wherein the removal assembly is separate from the platen assembly and does not move with the platen assembly.6. The additive manufacturing system of claim 1 , wherein the removal assembly comprises:a motor;a power screw configured to receive rotatable power ...

Automated additive manufacturing system for printing three-dimensional parts, printing farm thereof, and method of use thereof

An additive manufacturing system comprising a platen assembly configured to restrain and release a film or substrate, a head gantry configured to retain a print head for printing a three-dimensional part on the restrained film or substrate. The additive manufacturing system may also include a removal assembly configured to draw the film having the printed three-dimensional part from the platen assembly and to cut the drawn film.

Additive manufacturing system and method for printing three-dimensional parts using velocimetry

An additive manufacturing system that retains a print head for printing a three-dimensional part in a layer-by-layer manner using an additive manufacturing technique, where the retained print head is configured to receive a consumable material, melt the consumable material, and extrude the molten material. The system also includes a velocimetry assembly configured to determine flow rates of the molten material, and a controller assembly configured to manage the extrusion of the molten material from the print head, and to receive signals from the velocimetry assembly relating to the determined flow rates.

Print foundation positioning and printing methods for additive manufacturing system

Method for printing a three-dimensional part layerwise with an additive manufacturing system includes printing layers by depositing material from a print head onto a print foundation, incrementing a position of the print head relative to the print foundation after each layer is printed, and indexing the print foundation carrying the printed layers away from the print head along the printing axis after a number of layers are printed. Printing is performed with driven and fixed rails clamped against movement of the print foundation. Moving the print foundation includes moving the driven rails with respect to the fixed rails in a direction substantially perpendicular to the build plane. Additive manufacturing system includes a drive mechanism to index the print foundation on the printing axis using fixed and driven rails, the driven rails engaging the print foundation for moving the print foundation.

In-situ part position measurement

A probe for an additive manufacturing system includes a probe body having a first air port therethrough between an inlet and an outlet, and a location sensing probe extending from the probe body. The location sensing probe includes a probe end and a probe bar, the probe bar coupled between the probe body and the probe end, and a channel surrounding the probe bar, the channel having an inner tube having an inlet proximate the probe body and an outlet proximate the probe end. A method of determining a position of an item being printed in an additive manufacturing system, includes probing the position with a location sensing probe having a resolution finer than a print resolution of the print head.

MAGNETIC PLATEN ASSEMBLY FOR ADDITIVE MANUFACTURING SYSTEM

A platen assembly for use in an additive manufacturing system, which includes a platen plate that is preferably secured to a gantry mechanism of the additive manufacturing system, and having a top surface, and one or more magnets secured to the platen plate and configured to generate one or more magnetic fields at the top surface of the platen plate. The platen gantry is configured to magnetically couple interchangeable and replaceable build sheets to the top surface of the platen plate due to the one or more generated magnetic fields, and where the magnetically-coupled build sheets are configured to receive the printed layers from the printing mechanism. 1. An additive manufacturing system for printing a three-dimensional part , the additive manufacturing system comprising:a printing mechanism configured to print layers of the three-dimensional part; and a platen plate having a top surface; and', 'one or more magnets secured to the platen plate and configured to generate one or more magnetic fields at the top surface of the platen plate;', 'wherein the platen assembly is configured to magnetically couple a build sheet to the top surface of the platen plate due to the one or more generated magnetic fields, and wherein the magnetically-coupled build sheet is configured to receive the printed layers from the printing mechanism., 'a platen assembly comprising2. The additive manufacturing system of claim 1 , and further comprising the build sheet claim 1 , which comprises:a base sheet comprising one or more ferromagnetic materials; anda top film disposed on the base sheet and comprising one or more polymeric materials, wherein the top film defines a receiving surface for the build sheet to receive the printed layers.3. The additive manufacturing system of claim 2 , wherein the top film comprises an adhesive tape.4. The platen assembly of claim 1 , wherein the additive manufacturing system comprises an electrophotography-based additive manufacturing system claim 1 , and ...

Simplified tuning of 3d printers

A 3D printer includes a holding area holding material to be used to produce a part and at least one component for producing the part through layer-wise additive manufacturing. A data storage device in the 3D printer stores instructions for generating build parameter values, the instructions including empirically derived data, relationships, and/or equations. A processor in the 3D printer receives values for a public build parameter set and a category for the material wherein the category represents multiple different materials. The processor executes instructions to determine values for a private build parameter set that vary based on the properties of the material. The values for the private build parameter set are determined from the received values for the public build parameter set and the received category. The processor then uses the received values for the public build parameter set and the values for the private build parameter set to build the part.

SEMI-CRYSTALLINE CONSUMABLE MATERIALS FOR ELECTROPHOTOGRAPHY-BASED ADDITIVE MANUFACTURING SYSTEM

A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having a semi-crystalline thermoplastic material and a charge control agent. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner. 1. A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system , the part material comprising: a semi-crystalline thermoplastic material; and', 'a charge control agent;, 'a composition comprisingwherein the part material is provided in a powder form having a D50 particle size ranging from about 5 micrometers to about 30 micrometers; andwherein the part material is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.2. The part material of claim 1 , wherein the composition further comprises a heat absorber claim 1 , wherein the heat absorber constitutes from about 0.5% by weight to about 10% by weight of the part material.3. The part material of claim 1 , wherein the D50 particle size ranges from about 10 micrometers to about 20 micrometers.4. The part material of claim 1 , wherein the powder form also has a D901D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 1.40.5. The part material of claim 1 , wherein the charge control agent is selected from the group consisting of chromium oxy carboxylic acid complexes claim 1 , zinc oxy carboxylic acid complexes claim 1 , aluminum oxy carboxylic acid complexes claim 1 , and mixtures thereof.6. The part material of claim 1 , wherein the charge control agent constitutes from about ...

Protective filament guide tube for additive manufacturing system

An additive manufacturing system includes a substantially moisture-impermeable barrier comprising a guide tube assembly for supplying filament from a filament supply to a print head in an extrusion-based additive manufacturing system, where the print head melts the filament and extrudes the melted filament to form a 3D part. The guide tube assembly includes an inner tube permeable to moisture and an outer tube that s substantially moisture impermeable. The inner tube has an interior passageway configured to receive the filament, and has a relatively low coefficient of friction to minimize drag force as the filament travels through it. The outer tube surrounds the inner tube and provides a substantially moisture-impermeable barrier around the inner tube.

System and method for 3d construction printing

A large-scale additive manufacturing system for printing a structure includes an extrusion system and a knitting system. The extrusion system includes a nozzle configured to receive a supply of structural material and to selectively dispense the structural material in flowable form, and a first gantry configured to move the nozzle along toolpaths defined according to a structure to be printed such that structural material may be dispensed along the toolpaths to print a series of structural layers, wherein the series of structural layers bond together to form all or a portion of the structure. The knitting system includes a tow feeder configured to feed a supply of tow material to a location proximate a current course of loops extending above an upper surface of a current structural layer or extending above a base surface in regions where no structural layer has been printed, and a hooking device configured to engage the tow material and bring it through the current course of loops to form a subsequent course of loops interwoven with the current course of loops. A controller is configured to operate the knitting system to form additional subsequent courses of loops each interwoven with a current course of loops after each of the series of structural layers are printed, wherein the interwoven courses of loops create a reinforcement network of knitted loops embedded in the structure, and wherein the series of structural layers are tied together.

Support structure removal system

A support structure removal system comprising a vessel and a second component. The vessel comprises a vessel body, a porous floor configured to retain a three-dimensional part, and an impeller rotatably mounted below the porous floor. The second component comprises a surface configured to operably receive the vessel, and a rotation-inducing assembly located below the surface, where the rotation-inducing assembly is configured to rotate the impeller with magnetic fields when the vessel is received on the surface of the second component to agitate and direct flows of an aqueous fluid through the porous floor.

ADDITIVE MANUFACTURING METHOD FOR PRINTING THREE-DIMENSIONAL PARTS WITH PURGE TOWERS

A method for printing a three-dimensional part with an additive manufacturing system, the method including printing layers of the three-dimensional part and of a support structure for the three-dimensional part from multiple print heads or deposition lines, and switching the print heads or deposition line between stand-by modes and operating modes in-between the printing of the layers of the three-dimensional part and the support structure. The method also includes performing a purge operation for each print head or deposition line switched to the operating mode, where the purge operation includes printing a layer of at least one purge tower from the print head or deposition line switched to the operating mode.

THREE-DIMENSIONAL PARTS HAVING INTERCONNECTED HOLLOW PATTERNS, AND METHOD FOR GENERATING AND PRINTING THEREOF

A three-dimensional part printed using an additive manufacturing technique, which includes sets of printed cell layers, each defining an array of hollow cells with wall segments, and sets of printed transition layers, each being disposed between adjacent printed cell layers, where the sets of printed transition layers each comprise sloped walls that diverge from a first portion of the wall segments and that converge towards a second portion of the wall segments to interconnect the hollow cells of adjacent printed cell layers, and where the sloped walls of adjacent printed transition layers have printing orientations that are rotated from each other in a build plane.

Additive manufacturing method using tilted scanners

Additive manufacturing method includes providing a number of scanners with at least partially overlapping fields of view. The scanners are positioned such that respective optical axes thereof are at an angle relative to a normal part bed. The method includes positioning the fields of view such that a cumulative field of view is substantially equal to a surface area of a part bed. A layer of materials is applied to the part bed, and each scanner directs a beam from a laser emitter to the part bed to selectively fuse the material to produce a layer of a three-dimensional part.

ADDITIVE MANUFACTURING SYSTEM AND METHOD FOR PRINTING THREE-DIMENSIONAL PARTS USING VELOCIMETRY

An additive manufacturing system that retains a print head for printing a three-dimensional part in a layer-by-layer manner using an additive manufacturing technique, where the retained print head is configured to receive a consumable material, melt the consumable material, and extrude the molten material. The system also includes a velocimetry assembly configured to determine flow rates of the molten material, and a controller assembly configured to manage the extrusion of the molten material from the print head, and to receive signals from the velocimetry assembly relating to the determined flow rates. 1. An additive manufacturing system comprising:a print head for printing a three-dimensional part in a layer-by-layer manner using an additive manufacturing technique, wherein the print head is configured to receive a consumable material, melt the consumable material, and extrude the molten material;a velocimetry assembly configured to determine flow rates of the molten material; anda controller assembly configured to manage the extrusion of the molten material from the print head, and to receive signals from the velocimetry assembly relating to the determined flow rates.2. The additive manufacturing system of claim 1 , wherein the velocimetry assembly comprises:a light source, and optionally, one or more optical lenses, which are configured to route a light beam from the light source towards the molten material, wherein the molten material causes light rays of the light beam to scatter;a detector having a sensor configured to receive at least a portion of the scattered light rays, and to transmit the signals relating to the determined flow rates to the controller assembly.3. The additive manufacturing system of claim 2 , wherein the detector is positioned relative to the light source to receive the scattered light rays in a transmission-forward-scatter pattern.4. The additive manufacturing system of claim 2 , wherein the detector is configured to receive the ...

CONSUMABLE ASSEMBLY FOR USE IN EXTRUSION-BASED LAYERED DEPOSITION SYSTEMS

A consumable assembly comprising a container portion configured to retain a supply of filament, a guide tube connected to the container portion, and a pump portion connected to the guide tube. 140-. (canceled)41. A consumable assembly for use in an extrusion-based layered deposition system having a substrate assembly , a mount , a gantry configured to move the mount relative to the substrate assembly , and a loading bay offset from the mount , wherein the consumable assembly comprises: an outer casing configured to be received by the loading bay, and having an interior region; and', 'a spool rotatably retained within the interior region of the outer casing of the container, wherein a portion of a filament is wound on the spool;, 'a container comprising a casing, wherein part of the casing of the head is retainable by the mount in a manner that allows the head to be replaced with a second head of a second consumable assembly;', a first portion retained by the casing of the head, and having an inlet end located within the casing of the head; and', 'a second portion located outside of the head casing and having an extrusion tip; and, 'a liquefier tube comprising], 'a head comprising a first tube portion secured to the outer casing of the container, and having an inlet accessible to the interior region of the outer casing to receive successive segments of the filament fed from the spool;', 'a second tube portion having an outlet that is positioned at an angle relative to the inlet end of the liquefier tube to provide the successive segments of the fed filament to the inlet end of the liquefier tube; and', 'a flexibility and a length between the first and second tube portions such that, when the head is retained by the mount and the outer casing of the container is mounted to the loading bay, the gantry is capable of moving the mount with the retained head;', 'wherein the flexible tube interconnects the container and the head such that the head is removed from the mount ...

Additive manufacturing with soluble build sheet and part marking

A method for producing three-dimensional parts, which includes printing the three-dimensional parts and associated support structures onto soluble build sheets, marking each three-dimensional part with information relating to the three-dimensional part, and removing the associated support structures and the soluble build sheets from the printed three-dimensional parts with an aqueous solution using a support removal process. The markings remain applied to the three-dimensional parts after the support removal process, and preferably do not detract from aesthetic qualities of the three-dimensional parts.

Core-shell morphology of composite filaments for use in extrusion-based additive manufacturing systems

A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a matrix of a first base polymer and particles dispersed within the matrix, and a shell portion comprising a same or a different base polymer. The consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional part, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament and retain the particles within the roads of the printed part and do not penetrate the outer surface of the shell portion.

Consumable assembly for use in extrusion-based layered deposition systems

A consumable assembly comprising a container portion configured to retain a supply of filament, a guide tube connected to the container portion, and a pump portion connected to the guide tube.

LIQUEFIER ASSEMBLIES FOR ADDITIVE MANUFACTURING SYSTEMS, AND METHODS OF USE THEREOF

A liquefier assembly for use in an additive manufacturing system to print three-dimensional parts. In one aspect, the liquefier assembly includes a liquefier that is transversely compressible, and having an inlet end configured to receive a consumable material in a solid or molten state and an outlet end, a nozzle at the outlet end, and an actuator mechanism configured to transversely compress and expand the liquefier in a controlled manner In another aspect, the liquefier assembly is self heating. 1. A liquefier assembly for use in an additive manufacturing system to print three-dimensional parts , the liquefier assembly comprising:a liquefier having an inlet end and an outlet end offset along the longitudinal axis, wherein the liquefier is transversely compressible;a nozzle at the outlet end of the liquefier; andan actuator mechanism operably positioned proximate the liquefier and configured to controllably apply pressure to transversely compress the liquefier.2. The liquefier assembly of claim 1 , wherein the liquefier comprises a ribbon liquefier.3. The liquefier assembly of claim 1 , and further comprising one or more electrical lines configured to operably connect the actuator mechanism to a controller assembly of the additive manufacturing system.4. The liquefier assembly of claim 1 , wherein the actuator mechanism comprises one or more piezoelectric actuators.5. The liquefier assembly of claim 4 , and further comprising a frame wherein the frame comprises space apart flanges positioned on opposing sides of the liquefier tube wherein the actuator assembly further comprises one or more mechanisms configured to bias the flanges together.6. The liquefier assembly of claim 1 , and further comprising one or more heater assemblies configured to heat the liquefier.7. The liquefier assembly of claim 1 , and further comprising one or more sensors configured to measure compressions and expansions of the liquefier.8. The liquefier assembly of and further comprising at ...

Additive manufacturing system and process with precision substractive technique

An additive manufacturing system and process for producing three-dimensional parts, which includes forming layers of the three-dimensional part from a part material at a first resolution, and ablating selected voxels of the formed layers with a laser beam at a second resolution that is higher than the first resolution.

Method of printing parts in a layerwise manner with one or more internal woven panels under tension

A method of producing a part printed in a layer-wise manner includes providing a pre-fabricated starter piece with a first course of loops and printing a layer of a part by extruding one or more flowable thermoplastic materials about the existing course of loops such that an upper surface of the layer is at a selected height on the existing course of loops. The method includes knitting a next course of loops to the existing course of loops to form a portion of an internal woven reinforcement network, and printing a next layer of the part by extruding one or more flowable thermoplastic materials about the next course of loops such that an upper surface of the next layer is at a selected height on the next course of loops, wherein the next course of loops extends above the structure being printed and may function as an existing course of loops for subsequent knitting steps. The method includes repeating the knitting and printing steps to create an internal woven reinforcement network within the printed part until the part is completed. The starter piece and the course of loops extending from the second end of the completed part are engaged and heated to a temperature where the material is flowable. The reinforcement network is then placed into tension by applying a force to pull the starter piece and the course of loops in opposite directions from each other. The part is cooled to a temperature where the thermoplastic material solidifies such that the internal woven structure remains in tension.

Method for Printing Three-Dimensional Parts with Part Strain Orientation

A method and program for printing a three-dimensional part with an additive manufacturing system, the method including generating or otherwise providing strain data from a digital model of the three-dimensional part, orienting the digital model to align the directions of high tensile strain in a build plane, and printing the three-dimensional part in a layer-by-layer manner based on the oriented digital model with the additive manufacturing system. 1. A method for printing a three-dimensional part with an additive manufacturing system , the method comprising:providing a digital model of the three-dimensional part to a computer-based system;generating strain data from the digital model with the computer-based system;determining a dominant tensile strain direction for the digital model from the strain data with the computer-based system;orienting the digital model to align the dominant tensile strain direction in a build plane of the additive manufacturing system; andgenerating printing instructions from the oriented digital model with the computer-based system.2. The method of claim 1 , wherein generating the strain data comprises generating strain tensors for the digital model claim 1 , and wherein the method further comprises saving one or more files of the generated strain tensors to one or more storage media of the computer-based system.3. The method of claim 2 , wherein the generated strain tensors for the digital model comprise diagonalized strain tensors.4. The method of claim 1 , and further comprising:slicing the oriented digital model into a plurality of sliced layers with the computer-based system, wherein the plurality of sliced layers comprise a first sliced layer;separating the first sliced layer into a plurality of sub-regions with the computer-based system, wherein the plurality of sub-regions comprise a first sub-region;calculating volume-averaged tensile strains for the first sub-region from the strain data with the computer-based system;comparing, ...

Consumable filaments having reversible reinforcement for extrusion-based additive manufacturing

A consumable assembly for use with an additive manufacturing system to print three-dimensional parts, the consumable assembly including a supply device (e.g., a spool) and a filament supported by the supply device, where the filament has a composition comprising one or more elastomers and one or more reinforcing additives, and a filament geometry configured to be received by a liquefier assembly of the additive manufacturing system. The composition is preferably configured to be thermally and/or chemically modified to reduce its flexural modulus.

Ceramic support structure

A pre-ceramic support structure for additive manufacturing, that upon thermal processing, is soluble in various solvents.

Additive manufacturing system with sliding thermal isolator

An additive manufacturing system includes a build chamber with at least first and second side walls and top and bottom walls. A central deformable, thermal insulator has a first edge and a second edge, where a print head carriage is movably retained within the central deformable thermal insulator and is configured to move print heads within a build plane of the build chamber under control of a gantry. The system includes first and second dynamic thermal barriers each having a length between a proximal edge and a distal edge wherein the proximal edge is configured to be secured to the central deformable insulator and a distal edge is configured to be movably retained to the build chamber such that as the print head carriage moves laterally across the build plane, each dynamic thermal barrier moves with the central deformable insulator and print head carriage, and retains its length.

Electrophotography-Based Additive Manufacturing with Pre-Sintering

A method and system for printing a three-dimensional part, which includes producing a developed layer of a part material with one or more electrophotography engines of an additive manufacturing system, transferring the developed layer from the one or more electrophotography engines to a transfer assembly of the additive manufacturing system sintering the developed layer at the transfer assembly to produce a sintered contiguous film, cooling the sintered contiguous film down to a transfer temperature, and pressing the cooled sintered contiguous film into contact with an intermediate build surface of the three-dimensional part with a low applied pressure. 1. An additive manufacturing system for printing a three-dimensional part , the additive manufacturing system comprising:one or more electrophotography engines configured to develop the layers of the three-dimensional part from a part material;a transfer assembly configured to receive the developed layers from the one or more electrophotography engines;a pre-sintering heater configured to sinter the developed layers at the transfer assembly to provide sintered contiguous films;a build platform;a pressing element configured to engage with the transfer assembly to press the sintered contiguous films into contact with an intermediate build surface of the three-dimensional part on the build platform in a layer-by-layer manner;wherein the pre-sintering heater is located upstream along the transfer assembly from the pressing element such that the sintered contiguous films cool down to a transfer temperature prior reaching the pressing element.2. The additive manufacturing system of claim 1 , wherein the pressing element comprises a nip roller.3. The additive manufacturing system of claim 2 , wherein the pressing assembly further comprises a heating element configured to heat the nip roller to a temperature that is within about 15° C. below a glass transition temperature of the part material.4. The additive manufacturing ...

Filament drive for 3d printer

A low compressive force filament drive system for use with an additive manufacturing system includes a plurality of drives spaced from each other. Each drive includes a first rotatable shaft and a second rotatable shaft engaged with the first rotatable shaft in a counter rotational configuration. The filament drive system includes a pair of drive wheel, each fixedly attached to a shaft and comprising a groove about a circumference having a substantially smooth surface and positioned on opposing sides of a filament path with a gap therebetween so as to frictionally engage a filament provided in the filament path. The drive includes one or more bridge shafts, wherein each bridge shaft is configured to rotatably couple the adjacent drives of the plurality of drives, wherein the shafts are configured to be directly or indirectly driven by a motor. The counter rotating drive wheels pull the filament from a source and push the filament through a filament feed path to a feed drive in a print head without breaking or indenting a surface of the filament.

Filament with exterior barrier and method of producing same

A material for an additive manufacturing system having a build environment includes a filament coated with a barrier wherein barrier comprises less than about 1 wt % of the filament wherein the barrier substantially prevents the transmission of moisture or gasses into the filament.

Biodegradable polymer compositions

Hyper-branched biodegradable polymers are produced by melt processing biodegradable polymers with a branching agent at temperatures that promote free radical reactions between the biodegradable polymer and the branching agent. The biodegradable compositions have an excellent balance of mechanical properties and are suitable for flame retardant applications.

Apparatus and method for creating three-dimensional objects

Apparatus incorporating a movable dispensing head provided with a supply of material which solidifies at a predetermined temperature, and a base member, which are moved relative to each other along "X," "Y," and "Z" axes in a predetermined pattern to create three-dimensional objects by building up material discharged from the dispensing head onto the base member at a controlled rate. The apparatus is preferably computer driven in a process utilizing computer aided design (CAD) and computer-aided (CAM) software to generate drive signals for controlled movement of the dispensing head and base member as material is being dispensed. Three-dimensional objects may be produced by depositing repeated layers of solidifying material until the shape is formed. Any material, such as self-hardening waxes, thermoplastic resins, molten metals, two-part epoxies, foaming plastics, and glass, which adheres to the previous layer with an adequate bond upon solidification, may be utilized. Each layer base is defined by the previous layer, and each layer thickness is defined and closely controlled by the height at which the tip of the dispensing head is positioned above the preceding layer.

Method and apparatus for solid prototyping

An improved extrusion-based manufacturing system includes one or more extruders, with each extruder containing at least two stages of increasing pressurization. In a preferred embodiment, a first stage of pressurization is created by the motion of a solid wafer of thermoplastic through an orifice into a heater chamber. In another preferred embodiment, the wafers are stored in removable, electronically tagged, cassettes and are removed therefrom by a stapler mechanism which feeds the wafers from the cassette to a tractor feed mechanism on demand. In each embodiment, a second stage of pressurization is provided by a pump, with the first stage pressurization maintaining a flow of thermoplastic to the pump under all expected pump rates.

Support material for digital manufacturing systems

A support material feedstock comprising a first copolymer and a polymeric impact modifier, where the first copolymer includes a first monomer unit comprising a carboxyl group and a second monomer unit comprising a phenyl group.

Support material for digital manufacturing systems

A support material feedstock comprising a first copolymer and a polymeric impact modifier, where the first copolymer includes a first monomer unit comprising a carboxyl group and a second monomer unit comprising a phenyl group.

Biodegradable polymer compositions

Hyper-branched biodegradable polymers are produced by melt processing biodegradable polymers with a branching agent at temperatures that promote free radical reactions between the biodegradable polymer and the branching agent. The biodegradable compositions have an excellent balance of mechanical properties and are suitable for flame retardant applications.