An extrusion-based 3D printer (10) configured to print parts (74) in a layer-wise manner includes a build chamber (16) and an unheated region (18) above the build chamber (16). A print head (24) is located in the unheated region (18) and moves in an x-y plane across the build chamber (16) and is lifted and lowered in a z dimension where a nozzle (25) of the print head (24) is configured to extend into the build chamber (16) when the print head (24) is lowered. The printer (10) includes an umbilical (57) within the unheated region (18) configured to support a plurality of operational feeds (54, 70, 72), the umbilical (57) having a length between a first end and a second end that is configured to be coupled to the print head (24). The umbilical (57) includes a backbone (76) running the length of the umbilical (57) configured to provide support and flexibility to the plurality of operational feeds (54, 70, 72) and a plurality of fixtures (80) spaced along a length of the umbilical (57).
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B65H 57/00 - Guides for filamentary materials; Supports therefor
2.
POWDER COMPOSITION AND METHODS FOR POWDER BED FUSION ADDITIVE MANUFACTURING
The invention is in the field of additive manufacturing. There is provided a method for manufacturing a powder composition having a D50 particle size value of 20-150 microns suitable for powder bed fusion additive manufacturing processes, comprising the steps of: (a) providing a particulate starting material comprising a semicrystalline polymer; (b) optionally, compacting the starting material with a compacting pressure of >5 kN/cm2, thereby obtaining a compacted material; (c) optionally, reducing the size of the particulate starting material or the compacted material; (d) dry blending the starting material, the compacted material, or the size-reduced material with a pigment using high shear mixing; (e) optionally, size fractionating the starting material, the compacted material, the size-reduced material and/or the dry blended material. There is also provided a powder composition having a D50 particle size value of 20- 150 microns, preferably obtainable by a such a method, suitable for additive manufacturing powder bed fusion processes, comprising a semicrystalline polymer and a pigment, wherein the powder composition has a reflectance at 800 nm of 30 % or less, preferably 25 % or less. There is also provided an additive manufacturing method for the layerwise formation of a three-dimensional article from such a powder composition, wherein the method comprises a step of selectively fusing a cross section of the article within each of a plurality of successive layers by applying fusing radiation, as well as an article comprising a semicrystalline polymer, obtainable by a such a method.
The invention is in the field of additive manufacturing. There is provided a positive model of one or more teeth and/or gum, suitable for producing a dental aligner, the model comprising a polyhydroxyalkanoate (PHA). There is also provided such a model, comprising sintering or fusing a powder comprising a polyhydroxyalkanoate (PHA).
A61C 13/34 - Making or working of models, e.g. preliminary castings, trial dentures; Dowel pins
A61K 6/891 - Compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
A photo-curable composition can include a photo-curable resin and a photoinitiator. The photo-curable composition can typically include a (meth)acrylate-terminated prepolymer, a second prepolymer, and a reactive diluent.
A method includes providing values for a set of tunable build parameters (208) corresponding to a print job specification to a user interface, and in response to user modification or selection of the tunable build parameters (208), computing values for a set of additional build parameters (214). A data package (216,222) is created based on the values for the tunable build parameters (208) and the set of additional build parameters (214) and data files are then sent to one or more 3D printers (224,226) and one or more slicing programs (218, 220).
A consumable assembly for a 3D printer (10) includes a spool (208,210) carrying wound filament (202). The spool is configured to be installed into a spool cabinet (52) to maintain the filament in a controlled environment. A filament key fob (204) that carries a spool chip programmed with identification data for the consumable assembly is tethered to the spool. The filament key fob is configured to be received in a dock (68) of the 3D printer outside of a controlled environment of a chamber (54) of the spool cabinet while remaining tethered to the spool installed in the chamber of the spool cabinet.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29C 64/259 - Enclosures for the building material, e.g. powder containers interchangeable
B29C 64/307 - Handling of material to be used in additive manufacturing
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
7.
METHOD FOR POLYMERIZING SUPERFICIAL FEATURES IN 3D-PRINTED PARTS
A method includes: accessing a part model comprising a three-dimensional representation of a part; accessing a material profile relating exposure energy and three-dimensional polymerization geometry of a material selected for the part; segmenting the part model into a set of model layers; detecting a first upward-facing surface in the part model; defining a first model volume in a first model layer, adjacent the first upward-facing surface, and fully contained within the part model; based on the material profile, calculating a first exposure energy predicted to yield a first three-dimensional polymerization geometry approximating a first contour of the first upward-facing surface when projected onto the material during a build; populating a first print image with the first exposure energy in a first image area corresponding to the first model volume in the first model layer; and storing the first print image in a print file for the part.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
An induction sensing method for identifying the center of a tip surface of a nozzle (604) of print head of a 3D printer includes providing an eddy current sensor (610) in a fixed position and providing a metal nozzle (604) with a tip orifice in a main body and a tip surface about the tip orifice. The method includes moving the metal nozzle (604) over the eddy current sensor (610) in a predetermined motion path above the eddy current sensor (610) while the eddy current sensor remains stationary and samples the magnitude of inductance in a generated inductive field, thereby generating a curve representing the inductive field. The method includes identifying a maximum amplitude of the curve to identify the center of the tip surface.
G01B 7/00 - Measuring arrangements characterised by the use of electric or magnetic techniques
B29C 64/236 - Driving means for motion in a direction within the plane of a layer
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
A photo-curable composition can include a photo-curable resin and a photoinitiator. The photo-curable composition can typically have a shear viscosity of less than 1 Pa·s at 100 °C at a shear rate of 50 s-1 and can typically include a first prepolymer, a second prepolymer, and a reactive diluent.
A method for 3D printing a part with an additive manufacturing system includes printing a first portion (302)(308) of a part (342) in a layerwise manner and analyzing a topology (344) of the first portion (302)(308) of the part. The method includes determining a tool path for printing a second portion (306) of the part on a surface of the first portion (302) of the part (346), and pre-heating the first portion (302)(308) of the part along the tool path as a function of the topological analysis of the first portion of the part (348). The method includes printing the second portion (306) of the part along the tool path (350).
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
A 3D printer (10) includes a heated build chamber (16), a build platen (30) positioned within the heated build chamber (16), and a primary z-axis positioner (32) configured to move the build platen (30) in a z-direction within the heated build chamber (16). The 3D printer (10) also includes a tool chamber (18) positioned above the build chamber (16) and having an unheated, cooled, or room temperature environment. A thermal insulator (20) separates the build chamber (16) and the tool chamber (18). A print head carriage (26) of the 3D printer (10) is configured to engage one of the plurality of print heads and/or print head tools (24) stored in a tool rack (22) positioned within the tool chamber (18). The 3D printer (10) also includes a local Z positioner (72) configured to move the carriage (26) from a tool engagement z-height within the tool chamber (18), to a position where the engaged print head or print head tool (24) extends from the tool chamber (18) through the insulator (20) into the build chamber (16).
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/259 - Enclosures for the building material, e.g. powder containers interchangeable
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
A method for generating print images for additive manufacturing includes: accessing a part model; accessing a set of dimensional tolerances for the part model; and segmenting the part model into a set of model layers. The method also includes, and, for each model layer: detecting an edge in the model layer; assigning a dimensional tolerance to the edge; defining an outer exposure shell inset from the edge by an erosion distance inversely proportional to a width of the dimensional tolerance; defining an inner exposure shell inset from the outer exposure shell and scheduled for exposure separately from the outer exposure shell; defining an a outer exposure energy proportional to the width of the dimensional tolerance and assigned to the outer exposure shell; and defining an inner exposure energy greater than the outer exposure energy and assigned to the inner exposure shell.
Disclosed herein are expanding spinal fusion cage embodiments including an expandable cage assembly configured to expand from a collapsed state to an expanded state in an intervertebral space when inflated with a material. The assembly can include an inflatable section defining an interior volume configured to receive the material and expand the interior volume in response to a pressure from the received material to cause the expandable cage assembly to transition from the collapsed state to the expanded state, and a stabilization section configured to restrain the inflatable section during inflation.
A61F 2/44 - Joints for the spine, e.g. vertebrae, spinal discs
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
A large-scale additive manufacturing system (10) for printing a structure (17) includes an extrusion system (11, 12, 14, 16) and a knitting system (20). The extrusion system includes a nozzle (11) configured to receive a supply (14) of structural material and to selectively dispense the structural material in flowable form, and a first gantry (12) configured to move the nozzle (11) along toolpaths defined according to a structure (17) to be printed such that structural material (14) may be dispensed along the toolpaths to print a series of structural layers (231), wherein the series of structural layers (231) bond together to form all or a portion of the structure (17). The knitting system (20) includes a tow feeder (222) configured to feed a supply of tow material to a location proximate a current course of loops (31, 230) extending above an upper surface (244) of a current structural layer or extending above a base surface in regions where no structural layer has been printed, and a hooking device (228) configured to engage the tow material and bring it through the current course of loops (356) to form a subsequent course of loops (380) interwoven with the current course of loops (356). A controller (38) is configured to operate the knitting system (11, 12, 14, 16) to form additional subsequent courses of loops (380) each interwoven with a current course of loops (356) after each of the series of structural layers (231) are printed, wherein the interwoven courses of loops create (356, 380) a reinforcement network of knitted loops embedded in the structure (17), and wherein the series of structural layers (231) are tied together.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B33Y 99/00 - Subject matter not provided for in other groups of this subclass
B29C 70/68 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers
B29C 70/88 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
B28B 1/00 - Producing shaped articles from the material
B28B 23/00 - Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material
D04B 1/00 - Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
15.
FILAMENT DRIVE MECHANISM FOR USE IN ADDITIVE MANUFACTURING SYSTEM AND METHOD OF PRINTING 3D PART
A filament drive mechanism (100) for use with an additive manufacturing system (10) includes at least first and second drives (160, 170). Each drive includes a first rotatable shaft (110, 161) and a second rotatable shaft (172, 180) engaged with the first rotatable shaft (161, 172) in a counter rotational configuration. Each drive (160, 170) includes a pair of filament engagement elements (126, 166 and 178, 186), one on each rotatable shaft, and positioned on opposing sides of the filament path (218) with a gap therebetween so as to engage a filament provided in the filament path (218). The drive mechanism (100) includes a bridge follower (190) configured to rotatably couple the first drive (160) to the second drive (170) wherein one of the shafts (110, 172, 190) is a drive shaft configured to be driven by a motor at a rotational rate selected to advance the filament at a desired feed rate and to cause the other shafts to rotate at the same rotational rate, such that each pair of filament engagement teeth (126, 166 and 178, 186) will engage a filament in the filament path (218) and will coordinate to advance the filament while counter-rotating at the same rotational rate to drive the filament into a liquefier.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
16.
CORE-SHELL FILAMENT FOR USE IN EXTRUSION-BASED ADDITIVE MANUFACTURING SYSTEMS AND METHOD OF PRINTING PARTS
A filament (250, 300, 310) for use in an extrusion-based additive manufacturing system (10) includes an elastomeric core (256, 302, 312) and a harder, non-elastomeric shell (258, 304, 314, 316). The core (256, 302, 312) compositionally comprising an elastomeric core material having a flexural modulus of less than 31,000 psi and a durameter of less than 80 Shore. The shell (258, 304, 314, 316) overlays the core portion (256, 302, 312) and compositionally comprises a non-elastomeric thermoplastic shell material that is substantially miscible with the elastomeric core material, wherein the core material and the shell material have the same monomer chemistry. The non-elastomeric thermoplastic shell material has a flexural modulus that is greater than the flexural modulus of the elastomeric core material by at least a factor of five, wherein the shell (258, 304, 314, 316) provides sufficient strength or stiffness to the filament (250, 300, 310) such that filament (250, 300, 310) can be utilized as a feedstock in the extrusion-based additive manufacturing system (10).
D01F 8/04 - Conjugated, i.e. bi- or multicomponent, man-made filaments or the like; Manufacture thereof from synthetic polymers
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
A sulfonated water-dispersible thermoplastic copolymer material for use as a support material in an additive manufacturing process is made by a method comprising providing a selected thermoplastic copolymer having an acid or an anhydride group; esterifying the acid group of the selected thermoplastic copolymer with a hydroxyl-functionalized sulfonate salt, or amidizing the acid group of the selected thermoplastic copolymer with an amine sulfonate salt, or imidizing the anhydride group of the selected thermoplastic copolymer with an amine sulfonate salt. The esterification, the amidization or the imidization results in a sulfonated water thermoplastic dispersible copolymer having a glass transition temperature suitable to provide an effective support during the additive manufacturing process and wherein the sulfonated water-dispersible thermoplastic copolymer will disperse in tap wrater in less than 1 hour.
C08L 101/02 - Compositions of unspecified macromolecular compounds characterised by the presence of specified groups
C08L 101/14 - Compositions of unspecified macromolecular compounds characterised by physical features, e.g. anisotropy, viscosity or electrical conductivity the macromolecular compounds being water soluble or water swellable, e.g. aqueous gels
C08F 8/44 - Preparation of metal salts or ammonium salts
C08F 222/08 - Maleic anhydride with vinyl aromatic monomers
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
A water-dispersible addition-type sulfonated thermoplastic copolymer material for use as a consumable feedstock additive manufacturing, wherein the water-dispersible thermoplastic copolymer is a reaction product of an addition-type reaction of a metal sulfonated monomer, the water-dispersible sulfonated thermoplastic copolymer being dispersible in tap water in less than one hour.
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
B33Y 70/00 - Materials specially adapted for additive manufacturing
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A rotary additive manufacturing system (10) for producing 3D parts (44) in a layer-wise manner includes a silo support (14), a tool support (16), a plurality of silos (30), and a part developer (32). The tool support (16) overlays a first side of the silo support (14), and is configured to rotate about a central axis (18) relative to the silo support (14). The silos (30) are each attached to the silo support (14) and extend along the central axis (18) from a second side of the silo support (14) that is opposite the first side. The part developer (32) is supported by the tool support (16), and is configured to build a 3D part (44) within each of the silos (30) in a layer-by-layer manner during rotation of the tool support (16) relative to the silo support (14).
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
An additive manufacturing system (140) for printing three-dimensional parts (148), the system (140) including a build chamber (142) having an opening (143) with first and second opposing edges (131, 133), and a platen (132) in the build chamber (142). A baffle door (120) expandable across the opening (143) has a first baffle section (121) attached at the first opposing edge (131) and configured to extend between a first position adjacent the first opposing edge and a second position adjacent the second opposing edge (133), a second baffle section (122) attached at the second opposing edge (133) and configured to extend between a first position adjacent the second opposing edge (133) and a second position adjacent the first opposing edge (131), and a third baffle section (123) having a frame (125), a tool port (124) in the frame (125), and baffles on either side of the tool port (124), the baffles configured to expand and contract in a second direction substantially perpendicular to the first direction as the tool port (124) moves within the frame (125). The baffle door (120) insulates the build chamber (142). User access to the build chamber (142) is enabled by opening and closing the baffle door (120).
An additive manufacturing system (100) includes an extruder (150) having a motor (220) and a pressure sensor (232). A filter (700) receives speed values (504) for the motor (220) and generates a predicted pressure value (702) from the speed values (504). A response threshold module (706, 708) sets a response threshold pressure value based on the predicted pressure value (702) such that when the response threshold pressure value is between a pressure value (508) from the pressure sensor and the predicted pressure value (702), a response (516, 518) is executed.
A multiple axis robotic additive manufacturing system (100) includes a robotic arm (102) movable in six degrees of freedom. The system includes a build platform (106) movable in at least two degrees of freedom and independent of the movement of the robotic arm (102) to position the part (110) being built to counteract effects of gravity based upon part geometry. The system (100) includes an extruder (104) mounted at an end of the robotic arm (102). The extruder is configured to extrude at least part material with a plurality of flow rates, wherein movement of the robotic arm (102) and the build platform (106) are synchronized with the flow rate of the extruded material to build the 3D part (106).
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A method of printing a 3D part with an additive manufacturing system includes printing a first portion of the part and pre-heating the first portion of the part along an upcoming tool path to a temperature at or above a material- specific bonding temperature and below a degradation temperature of the material. Material is extruding material onto the first portion along the pre-heated tool path while the temperature along the part surface remains at or above a material- specific bonding temperature and below the degradation temperature of the material thereby forming a newly extruded road. The method includes cooling the newly extruded road along the pre-heated tool path to remove heat imparted by the preheating step such that a thermally stable temperature is reached, wherein the preheating, extruding and cooling is performed in less than ten seconds.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
An additive manufacturing system (100) includes an extruder (118) that includes a drive mechanism (124), a nozzle (122), and a pressure sensor (140). The drive mechanism is configured to feed a molten consumable material. The nozzle is attached at a distal end (132) of the extruder and includes a nozzle tip (127), through which the molten consumable material is discharged as an extrudate. A pressure interface (146) is fluidically coupled to an interior cavity (142) of the nozzle. The pressure sensor is configured to operably measure a pressure within the interior cavity of the nozzle through the pressure interface.
An additive manufacturing system (10) includes a build chamber with at least first and second side walls and top and bottom walls. A central deformable, thermal insulator (30) has a first edge (32) and a second edge (33), where a print head carriage (31) is movably retained within the central deformable thermal insulator (30) and is configured to move print heads (204, 206) within a build plane of the build chamber under control of a gantry. The system (10) includes first and second dynamic thermal barriers (12, 14) each having a length between a proximal edge (16, 116) and a distal edge (18, 118) wherein the proximal edge (16, 116) is configured to be secured to the central deformable insulator (30) and a distal edge (18, 118) is configured to be movably retained to the build chamber such that as the print head carriage (31) moves laterally across the build plane, each dynamic thermal barrier (12, 14) moves with the central deformable insulator (30) and print head carriage (31), and retains its length.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
26.
WATER SOLUBLE SUPPORT MATERIALS FOR HIGH TEMPERATURE ADDITIVE MANUFACTURING APPLICATIONS
A polymeric blend includes a blend of polyvinylpyrrolidone (PVP) polymers. The polymeric material includes a blend of at least two PVP polymers wherein at least one of the PVP polymers has an average molecular weight of about 40,000 daltons or greater. The support material can be thermally stable at temperatures above 80°C. The support material is disintegrable in aqueous solutions such as tap water.
A support material for use in an additive manufacturing system includes a copolymer of vinyl pyrrolidone (VP) monomers and elastomeric monomers. The elastomeric monomers and the VP monomers are covalently bonded and copolymerized. The support material is thermally stable even at temperatures above 80°C and is disintegrable in aqueous solutions such as tap water.
Additive manufacturing system (100, 2400) includes a removable print foundation (106) and a drive mechanism configured to index the removable print foundation (106) horizontally along a printing axis (120), the drive mechanism including a gantry (108) having a frame with a plurality of support rails (1410), and a drive system configured to move the print foundation (106) along the gantry (108). A layerwise method for printing a three- dimensional item (2402with an additive manufacturing system (100, 2400) includes printing a plurality of layers of the three-dimensional item by depositing material from a print head (110) onto a print foundation (106) of the additive manufacturing system (100, 2400), incrementing a position of the print head (110) relative to the print foundation (106) after each layer is printed, indexing the print foundation (106) carrying the printed layers away from the print head (110) along a printing axis (120) after the plurality of layers are printed, using a drive mechanism. Printing, incrementing and indexing are repeated to build the three- dimensional item. The print foundation (106) is removed from the three-dimensional item when the three-dimensional item exceeds a pre-determined length.
A viscosity pump assembly (10) for use in an additive manufacturing system includes a viscosity pump (12) having a pump chamber (26) configured to receive a supply of a consumable material from an inlet (70) and the pump chamber (26) having an outlet (24) configured to extrude the consumable material therefrom. An impeller (14) extends into the pump chamber (26) and has an axis of rotation (41), where the impeller (14) is configured to provide a rotational force to pump the consumable material through the outlet (24) and is configured to be moved parallel to the axis of rotation (41). An impeller actuator (47) is coupled to the impeller (14) and configured to move the impeller parallel to the axis of rotation (41). A sensor assembly (76) positioned at least partially within the pump chamber (26) is configured to sense a level of the consumable material in the pump chamber (26). A controller (100) is configured receive a signal from the sensor assembly (76) related to the level of the consumable material within the pump chamber (26) which that can be correlated to a volume of consumable material within the pump chamber (26) and compared to a volumetric flow rate set point and wherein the controller (100) is configured to send a signal to the impeller actuator (47) to move the impeller (14) parallel to the axis of rotation (41) to adjust the volumetric flow rate relative to the volumetric flow rate set point.
B29C 67/00 - Shaping techniques not covered by groups , or
B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
A water dispersible sulfopolymer for use as a material in the layer-wise additive manufacture of a 3D part made of a non water dispersible polymer wherein the water dispersible polymer is a reaction product of a metal sulfo monomer, the water dispersible sulfo- polymer being dispersible in water resulting in separation of the water dispersible polymer from the 3D part made of the non water dispersible polymer.
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.
B29C 67/00 - Shaping techniques not covered by groups , or
C08L 67/00 - Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
C08L 67/04 - Polyesters derived from hydroxy carboxylic acids, e.g. lactones
C08L 71/00 - Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
C08L 77/06 - Polyamides derived from polyamines and polycarboxylic acids
C08L 79/08 - Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
B33Y 70/00 - Materials specially adapted for additive manufacturing
32.
SURFACE ANGLE MODEL EVALUATION PROCESS FOR ADDITIVE MANUFACTURING
A method (10) for printing a three-dimensional part (24) in an additive manufacturing process, which includes calculating surface plane angles (30) relative to one or more of the coordinate axes as a function of surface area of the surface geometry, calculating a build score (32) for each coordinate axis as a function of the calculated surface plane angles (30), and selecting an orientation (64) for the digital model in the coordinate system based at least in part on the calculated build scores (32). The build scores (32) preferably predict which part orientations (64) are likely to provide good surface quality for the printed three-dimensional part.
A method of printing a three-dimensional part (120) includes dividing each of a plurality of layers of a model of the three-dimensional part (120) into a plurality of passes (502), where each of the plurality of passes (502) is separated from one or more adjacent passes by a gap. The gap between passes in a first layer (500) is offset from the gap between passes (502) in an adjacent layer, such that the gap between passes (502) in the first layer does not align with or stack with the gap between passes in the adjacent layer (500).
A slot extruder (14) for use with an additive manufacturing system (10), which includes a plenum (64) configured to receive a photocurable resin, an elongated slot (76) positioned at a bottom end of the plenum (64) and configured to receive the photocurable resin from the plenum (64), one or more resin inlet ports (70) extending into the plenum (64), and one or more mechanisms (72) configured to controllably pressurize and depressurize the photocurable resin in the plenum (64).
B29C 67/00 - Shaping techniques not covered by groups , or
B29C 39/14 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of indefinite length
B29C 39/00 - Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 31/02 - Dispensing from vessels, e.g. hoppers
B29C 35/02 - Heating or curing, e.g. crosslinking or vulcanising
A laser assembly (12) for use with an additive manufacturing system (10), which includes a base block (50) configured to be moved along a scan direction axis in the additive manufacturing system, a plurality of laser emitters (30) preferably arranged in an array of at least two rows of two or more laser emitters. At least a portion of a heat sink assembly (74) is configured to draw heat away from the base block and/or the laser emitters. The assembly includes a controller assembly (26) a controller assembly configured to control a movement of the base block along the first axis and to independently control at least timing and duration of energy emitted from each laser emitter of the plurality of laser emitters as the base block moves along the first axis.
A support material for use in an additive manufacturing system (10) to print a support structure (32) for a three-dimensional part. The support material includes a base resin that is substantially miscible with a part material used to print the three-dimensional part, and has a glass transition temperature within about 10°C of a glass transition temperature of the part material. The support material also includes a dispersed resin that is substantially immiscible with the base resin, where the base resin and the dispersed resin are each thermally stable for use in the additive manufacturing system (10) in coordination with the part material.
C08L 81/00 - Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen, or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
B29C 41/00 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
B29C 67/00 - Shaping techniques not covered by groups , or
C08L 71/00 - Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
37.
PRINT ASSEMBLY FOR ADDITIVE MANUFACTURING SYSTEM, AND METHODS OF USE THEREOF
A print assembly 18 for use in an additive manufacturing system 10 to print three-dimensional parts 12, which includes a coarse positioner 40, a fine positioner 42, and a liquefier assembly 20, where a portion of the liquefier assembly 20 is operably mounted to the fine positioner 42 such that the fine positioner 42 is configured to move the portion of the liquefier assembly 20 relative to the coarse positioner 40.
B29C 67/00 - Shaping techniques not covered by groups , or
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
38.
LIQUEFIER ASSEMBLIES FOR ADDITIVE MANUFACTURING SYSTEMS, AND METHODS OF USE THEREOF
A liquefier assembly (20) for use in an additive manufacturing system (10) to print three-dimensional parts (12). In one aspect, the liquefier assembly (20) includes a liquefier (52) that is transversely compressible, and having an inlet end (64) configured to receive a consumable material (48) in a solid or molten state and an outlet end (66), a nozzle (56) at the outlet end, and an actuator mechanism (62) configured to transversely compress and expand the liquefier (52) in a controlled manner. In another aspect, the liquefier assembly (20) is self heating.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B29C 67/00 - Shaping techniques not covered by groups , or
39.
GEAR-BASED LIQUEFIER ASSEMBLY FOR ADDITIVE MANUFACTURING SYSTEM, AND METHODS OF USE THEREOF
A liquefier assembly (20) for use in an additive manufacturing system (10) to print three-dimensional parts (22), which includes an upstream pressure-generating stage (52) and downstream flow-regulating stage (52). The upstream pressure-generating stage (52) includes a drive mechanism (46), a liquefier configured (52) to melt a consumable material (48) receive from the drive mechanism (46) to produce a molten material in a pressurized state. The downstream flow-regulating stage (52) includes a gear assembly (52) having a casing assembly (64,66,68) and a pair of gears (74,76) disposed within the interior cavity (78,80) and engaged with each other to regulate a flow of the pressurized molten material (48) through the gear assembly (52) for controlled extrusion.
An assembly for use in an additive manufacturing system (10) to print a three-dimensional part (22) that includes an extruder (20) comprising a gear (74) and a motor (84) that turns the gear (74), wherein rotation of the gear (74) regulates a flow of material out of the extruder (20). A controller (38), provides a control signal to the motor (84) to control the rate at which the motor (84) turns the at least one gear (74) and incorporates a time- varying signal into the control signal to reduce ripples in the material output by the extruder (20).
B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
B29C 47/08 - Component parts, details or accessories; Auxiliary operations
A support material for use in an additive manufacturing system, which includes a thermoplastic copolymer polymerized from monomers comprising acid-functional monomers having carboxylic acid groups, and one or more non-acid-functional monomers, where a portion of the carboxylic acid groups are neutralized with a base having an alkali metal cation. The thermoplastic copolymer has a high glass transition temperature and melt processing temperature, and is thermally stable at its melt processing temperature. The neutralized thermoplastic copolymer is soluble in an alkaline aqueous solution.
A method and system (10) for printing a three-dimensional part (86), which includes rotating a transfer belt (22) with a developed layer (64), scanning the developed layer (64) on the rotating transfer belt (22), pressing the developed layer (64) into contact with an intermediate build surface (88) of the three-dimensional part (86) retained on a moveable build platform (80), scanning the pressed layer on the three-dimensional part (88), comparing the scanned layers to detect an overlay error, and adjusting a position of the moveable build platform (80) relative to the transfer belt (22) to reduce the overlay error for a subsequent developed layer.
A method and system (10) for printing a three-dimensional part (74), which includes producing a developed layer (64) of a part material with one or more electrophotography engines (12) of an additive manufacturing system (10), transferring the developed layer (64) from the one or more electrophotography engines (12) to a transfer assembly (14) of the additive manufacturing system (10) sintering the developed layer (64) at the transfer assembly (14) to produce a sintered contiguous film (64F), cooling the sintered contiguous film (64F) down to a transfer temperature, and pressing the cooled sintered contiguous film (64F) into contact with an intermediate build surface (76) of the three-dimensional part (74) with a low applied pressure.
An additive manufacturing system (10) for printing a three-dimensional part (80), which includes one or more electrophotography engines (12) configured to develop layers (64) of the three-dimensional part (80), a rotatable transfer belt (22) configured to receive the developed layers (64) from the electrophotography engine(s) (12), a detector (38) configured to measure powder densities of the developed layers (64) on the rotatable transfer belt, and to transmit signals relating to the measured powder densities to a controller assembly (40), and a printing assembly (20) configured to receive the developed layer (64) from the rotatable transfer belt (22) and to print the three-dimensional part (80) from the developed layers (64)
An additive manufacturing system (10) and process for printing a three-dimensional part (74), which includes one or more electrophotography engines (12) configured to develop layers (64) of the three-dimensional part (74), a printing assembly (20) configured to print the three-dimensional part (74) from the developed layers (64), and a planarizer (40) configured to conduct solvent-assisted penalizations on intermediate build surfaces (76) of the three-dimensional part (74) after one or more of the developed layers (74) are printed.
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B41J 3/407 - Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
46.
ADDITIVE MANUFACTURING WITH VIRTUAL PLANARIZATION CONTROL
A method and system (10) for printing a three-dimensional part (80), which includes printing a plurality of successive layers of the three-dimensional part (80) with the additive manufacturing system (10) based on bitslices (116) in a bitslice stack (118), measuring surface heights of the successive layers after each of the successive layers are printed, determining differences between the measured surface heights and predicted stack heights of the bitslices (116), identifying one or more topographical error regions based on the determined differences, and modifying the bitslice stack (118) to compensate for the one or more topographical error regions.
B29C 67/00 - Shaping techniques not covered by groups , or
G03G 17/00 - Electrographic processes using patterns other than charge patterns, e.g. an electric conductivity pattern; Processes involving a migration, e.g. photoelectrophoresis, photoelectrosolography; Processes involving a selective transfer, e.g. electrophoto-adhesive processes; Apparatus essentially involving a single such process
G03G 15/00 - Apparatus for electrographic processes using a charge pattern
47.
METHOD FOR PRINTING THREE-DIMENSIONAL PARTS WTIH CRYSTALLIZATION KINETICS CONTROL
A method for printing a three-dimensional part (30) with an additive manufacturing system (10), which includes providing a part material that compositionally has one or more semi-crystalline polymers and one or more secondary materials that are configured to retard crystallization of the one or more semi-crystalline polymers, where the one or more secondary materials are substantially miscible with the one or more semi- crystalline polymers. The method also includes melting the part material in the additive manufacturing system (10), forming at least a portion of a layer of the three-dimensional part (30) from the melted part material in a build environment (12), and maintaining the build environment (12) at an annealing temperature that is between a glass transition temperature of the part material and a cold crystallization temperature of the part material.
A consumable assembly (22) for use with an additive manufacturing system (10) to print three-dimensional parts (30), the consumable assembly (22) including a supply device (e.g., a spool (118)) and a filament (52) supported by the supply device, where the filament (52) 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 (44) of the additive manufacturing system (10). The composition is preferably configured to be thermally and/or chemically modified to reduce its flexural modulus.
A liquefier assembly (20) for use in an additive manufacturing system (10), which includes a liquefier tube (58), one or more heater assemblies (56a, 56b) in contact with the liquefier tube (58), and configured to heat the liquefier tube (58) in a zone -by-zone manner, preferably one or more thermal resistors (60a, 60b) disposed adjacent to the heater assemblies (56a, 56b), and preferably one or more sensors (66) configured to operably measure pressure within the liquefier tube (58). The one or more heater assemblies (56a, 56b) may be operated to provide dynamic heat flow control.
A support material for printing a support structure (82) with an electrophotography-based additive manufacturing system (10), the support material including a composition having a charge control agent and a thermoplastic copolymer having aromatic groups, (meth)acrylate -based ester groups, carboxylic acid groups, and anhydride groups, with a high anhydride conversion. The composition is provided in a powder form having a controlled particle size, and the support material is configured for use in the electrophotography-based additive manufacturing system (10) having a layer transfusion assembly (20) for printing the support structure (82) in a layer-by-layer manner, and is at least partially soluble in an aqueous solution.
A part material for printing three-dimensional parts (80) with an electrophotography-based additive manufacturing system (10), 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 (10) having a layer transfusion assembly (20) for printing the three-dimensional parts (80) in a layer-by-layer manner.
A part material for printing three-dimensional parts (80) with an electrophotography-based additive manufacturing system (10), the part material including a composition having a copolymer (including acrylonitrile units, butadiene units, and aromatic units), a charge control agent, and a heat absorber. 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 (10) having a layer transfusion assembly (20) for printing the three-dimensional parts (80) in a layer-by-layer manner.
An additive manufacturing system (1) that retains a print head (18) for printing a three-dimensional part (20) in a layer-by-layer manner using an additive manufacturing technique, where the retained print head (18) is configured to receive a consumable material (64), melt the consumable material (64), and extrude the molten material (72). The system also includes a velocimetry assembly (66) configured to determine flow rates of the molten material (72), and a controller assembly (46) configured to manage the extrusion of the molten material (72) from the print head (18), and to receive signals from the velocimetry assembly (66) relating to the determined flow rates.
A method for printing a three-dimensional part (20) with an additive manufacturing system (10), the method including printing layers of the three-dimensional part (20) and of a support structure (22) for the three-dimensional part (20) from multiple print heads (18) or deposition lines, and switching the print heads (18) or deposition line between stand-by modes and operating modes in-between the printing of the layers of the three-dimensional part (20) and the support structure (22). The method also includes performing a purge operation for each print head (18) or deposition line switched to the operating mode, where the purge operation includes printing a layer of at least one purge tower (24) from the print head (18) or deposition line switched to the operating mode.
An additive manufacturing system (10) comprising a platen assembly (32) configured to restrain and release a film or substrate (48), a head gantry (40) configured to retain a print head (18) for printing a three-dimensional part (22) on the restrained film or substrate (48). The additive manufacturing system (10) may also include a removal assembly (34) configured to draw the film (48) having the printed three-dimensional part (22) from the platen assembly (32) and to cut the drawn film (48).
A consumable material (52) for use in an additive manufacturing system (10), the consumable material (52) 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 (10) for printing a three-dimensional part (30) from the consumable material (52) in a layer-by-layer manner using an additive manufacturing technique. The consumable material (52) is preferably capable of printing three-dimensional parts (30) having good part strengths and ductilities, and low curl.
An additive manufacturing system (30) for printing three-dimensional parts (50), the system (30) comprising a heatable region (34), a receiving surface (36a), a print head (40) configured to print a three-dimensional part (50) onto the receiving surface (36a) in a layer-by-layer manner along a printing axis, and a drive mechanism (38) configured to index the receiving surface (36a) along the printing axis such that the receiving surface (36a) and at least a portion of the three-dimensional part (50) move out of the heatable region (34).
A nozzle (68) for printing three-dimensional parts (52) with an additive manufacturing system (36), the nozzle (68) comprising a nozzle body (78) having an inlet end (80) and a tip end (82) offset longitudinally from the inlet end (80), a tip pipe (86) for extruding a flowable material, an inner ring (90) extending circumferentially around the tip pipe (86) at the outlet end (80), an outer ring (92) extending circumferentially around the inner ring (90), at least one annular recessed groove (94) located circumferentially between the inner ring (90) and the outer ring (92).
The deposition of graphene is accomplished by various techniques that result in a change of the graphene's solubility in the liquid medium. The solubility change enables the deposition of the graphene onto the substrate. Once the graphene is deposited onto the substrate, the at least partially coated substrate may be separated from the liquid medium. The substrates may then serve as a carrier to deliver the graphene to a desired application.
A universal adapter (18) for use with a consumable assembly (12) that is configured for use with an additive manufacturing system (10), the universal adapter (18) comprising an inlet opening (46a) configured to receive a guide tube (16) of the consumable assembly (12), and a connection member (52) at the outlet end (50), which is configured interface with a mating panel (44) of the additive manufacturing system (10).
An additive manufacturing system (10) comprising a transfer medium (14, 114, 214) configured to receive the layers (28, 128, 228) from a imaging engine (12), a heater (32, 132, 232) configured to heat the (28, 128, 228) layers on the transfer medium (14, 114, 214), and a layer transfusion assembly (33, 133, 233) that includes a build platform (18, 118, 218), and is configured to transfuse the heated layers (28, 128, 228) onto the build platform (18, 118, 218) in a layer-by-layer manner to print a three-dimensional part (22, 122, 222).
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/20 - Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B41J 3/407 - Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
B29C 67/00 - Shaping techniques not covered by groups , or
63.
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 (112) of cells (114) for a tree data structure of a digital part (46), where the cells (114) define a plurality of cell arrays (120), and pinging the cells (114) of one of the cell arrays (120) until a cell (114) containing a subset of the tree data structure is reached or until each cell (114) in the cell array (120) is pinged, where if a cell (114) containing the subset of the tree data structure is reached, then designating the reached cell (114) and all remaining unpinged cells (114) in the cell array (120) as filled. The method also includes repeating the pinging step for each remaining cell array (120) 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.
A method for building a three-dimensional part (24, 124), the method comprising providing a printed three-dimensional part (24, 124) and support structure (26, 126), where the support structure (26, 126) comprises at least two polymers having different glass transition temperatures. The method also comprises annealing the three-dimensional part (24, 124).
An additive manufacturing system (14, 114, 314) for printing a chocolate confection (16, 316), the system (14, 114, 314) comprising a platen (20, 120, 320), 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 (26, 126, 326) the print head (26, 126, 326) 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 (20, 120, 320) to print at least a portion of the chocolate confection (16, 316) based on the commands from a controller (30).
A print head assembly (43) that includes a print head carriage (18) and multiple, replaceable print heads (36, 42) that are configured to be removably retained in receptacles (46, 48) of the print head carriage (18).
A print head assembly (43) that includes a print head carriage (18) and multiple, replaceable print heads (36, 42) that are configured to be removably retained in receptacles (46, 48) of the print head carriage (18). The print heads (36, 42) each include a cartridge assembly (60, 64) and a liquefier pump assembly (64, 66) retained by the cartridge assembly (60, 64).
A liquefier assembly (62, 162, 262, 362, 462, 562, 662) for use in an extrusion-based additive manufacturing system (10), the liquefier assembly (62, 162, 262, 362, 462, 562, 662) comprising a downstream portion (62b, 162b, 262b, 362b, 462b, 562b, 662b) having a first average inner cross-sectional area, and an upstream portion (62a, 162a, 262a, 362a, 462a, 562a, 662a) having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion (62a, 162a, 262a, 362a, 462a, 562a, 662a) defining a shoulder (88, 188, 288, 388, 488, 588, 688) configured to restrict movement of a melt meniscus (94, 194, 294, 394, 494, 594, 694) of a consumable material (90, 190, 290, 390, 490, 590, 690).
A consumable filament (34, 134, 234) for use in an extrusion-based additive manufacturing system (10), where the consumable filament (34, 134, 234) comprises a first portion (36, 136, 236) of a first semi-crystalline polymeric material, and a second portion (38, 138, 238) 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.
An optical encoder (14, 514) comprising a set of light sources (54, 154, 354, 554) configured to emit light rays in a serial manner, an encoded scale (44, 344, 544) configured to reflect at least a portion of the emitted light rays, and a photodetector (56, 156, 356, 556), where the photodetector (56, 156, 356, 556) is configured to detect at least a portion of the reflected light rays and to generate signals based on the detected light rays for each of the light sources (54, 154, 354, 554).
G01D 5/347 - Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using optical means, i.e. using infrared, visible or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells using displacement encoding scales
G01B 11/00 - Measuring arrangements characterised by the use of optical techniques
71.
METHOD FOR GENERATING AND BUILDING SUPPORT STRUCTURES WITH DEPOSITION-BASED DIGITAL MANUFACTURING SYSTEMS
A method for building a support structure (28) with a deposition-based digital manufacturing system (10), the method comprising generating a convex hull polygon (80) based on a boundary polygon (72) of a layer (28a) of the support structure (28), offsetting the convex hull polygon (80) inward, offsetting the boundary polygon (72) outward, and generating an intersection boundary polygon (86) based at least in part on the offset boundary polygon (84) and the offset convex hull polygon (82).
An automated support cleaning system (10) comprising a tank (20) disposed within a housing (12, 14) and configured to circulate an aqueous cleaning solution to remove a support structure from a three-dimensional model.
B08B 3/10 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
B29C 67/00 - Shaping techniques not covered by groups , or
73.
ENCODED CONSUMABLE MATERIALS AND SENSOR ASSEMBLIES FOR USE IN ADDITIVE MANUFACTURING SYSTEMS
A consumable material (44, 58, 74, 204, 304) and sensor assembly (24, 26, 200, 300) for use in an additive manufacturing system (10), the consumable material (44, 58, 74, 204, 304) comprising an exterior surface (48, 64, 82, 322) having encoded markings (50, 68, 84, 320) that are configured to be read by the sensor assembly (24, 26, 200, 300), where the consumable material (44, 58, 74, 204, 304) is configured to be consumed in the additive manufacturing system (10) to build at least a portion of a three-dimensional model (28, 30).
A ribbon liquefier (38) comprising an outer liquefier portion (66) configured to receive thermal energy from a heat transfer component (40), and a channel (72) at least partially defined by the outer liquefier portion (66), where the channel (72) has dimensions that are configured to receive a ribbon filament (44), and where the ribbon liquefier (38) is configured to melt the ribbon filament (44) received in the channel (72) to at least an extrudable state with the received thermal energy to provide a melt flow. The dimensions of the channel (72) are further configured to conform the melt flow from an axially- asymmetric flow to a substantially axially-symmetric flow in an extrusion tip (52) connected to the ribbon liquefier (38).
A consumable material (34) for use in an extrusion-based digital manufacturing system (10), the consumable material (34) comprising a topographical surface pattern (40) that is configured to engage with a drive mechanism (56) of the extrusion-based digital manufacturing system (10).
A consumable material (34) for use in an extrusion-based digital manufacturing system (10), the consumable material (34) comprising a length (36) and a cross-sectional profile (38) of at least a portion of the length (36) that is axially asymmetric. The cross-sectional profile (38) is configured to provide a response time with a non- cylindrical liquefier (48) of the extrusion-based digital manufacturing system (10) 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.
A compounding system (12, 112, 212) for forming a customized consumable material (60, 160, 260), comprising a plurality of drive mechanisms (48a-48c, 148a-148c, 248a-248c) configured to feed stock materials at independent rates, and an extrusion component (50, 150, 250) configured to receive the fed stock materials, and further configured to at least partially melt and blend the received stock materials to provide the consumable material (60, 160, 260) in an extrudable state. Upon solidifying, the consumable material (60, 160, 260) comprises customized characteristics based on characteristics of the stock materials.
B29C 67/00 - Shaping techniques not covered by groups , or
D01D 5/00 - Formation of filaments, threads, or the like
D01D 5/28 - Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
A filament spool (70, 310) for use in a filament spool container (10, 12), where the filament spool (70, 310) comprises a first rim (312) and a second rim (314) offset by an axial shaft (316), and a series of grooves (332a-332d, 334a-334d) extending along a first portion of the first rim (312) and configured to receive a filament (72) of a material while the filament (72) is wound around the axial shaft (316) in a first rotational direction.
A container (10, 12) comprising a housing (22, 222) that is configured to rotatably mount a filament supply spool (70, 310), and a filament guide mechanism (56, 256) mountable within a channel (58, 258) of the housing (22, 222), where the filament guide mechanism (56, 256) comprises a filament pathway (138) configured to guide the filament (72) from the filament supply spool (70, 310) rotatably mounted in an interior chamber, and a sensor (148) configured to detect the presence of the filament (72) through at least a portion of the filament pathway (138).
A support material feedstock (36) 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.
A digital manufacturing system (10) for producing first and second objects (26A, 26B), the system comprising a platen (22), a gantry (20), a extrusion head system assembly and first and second sets of extruders (24A, 24B). The platen (22) defines a workspace upon which the objects (26A, 26B) are produced. The gantry (20) defines a headspace displaced from the workspace. The extrusion head system is mounted to the gantry (20) for movement in the headspace. The sets of extruders (24A, 24B) are connected to the extrusion head system and are configured to deposit extrusion material on the workspace to build the objects (26A, 26B). Each set of extruders (24A, 24B) comprises a first extruder (42A, 42B) mounted to the extrusion head system; a second extruder (44A, 44B) mounted to the extrusion head system so as to be actuatable from a first to a second position; and a flexible linkage (54) connecting the extruders (24A, 24B). The flexible linkages (54) position the second extruders (44A, 44B) in approximately equal known spatial relationships to the first extruders (42A, 42B) in the second positions.
B29C 67/00 - Shaping techniques not covered by groups , or
B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
A system (10) and method is provided for vapor smoothing a rapid manufactured three-dimensional object. A cabinet housing (12) has a sealable interior (16). A heated vapor chamber (18) in the interior (16) of the cabinet housing (12) contains solvent that is vaporizable to fill the vapor chamber (18) with vapor for smoothing the object when the object is placed in the vapor chamber (18). A drying chamber (20) is also provided in the interior (16) of the cabinet housing (12) that is separate from the vapor chamber (18) for drying the object when the object is moved from the vapor chamber (18) to the drying chamber (20).
A digital manufacturing system (10) comprises a build chamber (14), a build platform (32) disposed within the build chamber (14), at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head (40) disposed within the build chamber (14) and configured to deposit the heated metal-based alloy onto the build platform (32) in a predetermined pattern, an umbilical (56) having a first end located outside of the build chamber (14) and a second end connected to the deposition head (40), and at least one gantry assembly (16, 38) configured to cause relative motion between the build platform (32) and the deposition head (40) within the build chamber (14), where the at least one gantry assembly (16, 38) comprises a motor (28, 34, 36) disposed outside of the build chamber (14).
B29C 41/02 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
84.
FILAMENT DRIVE MECHANISM FOR USE IN EXTRUSION-BASED DIGITAL MANUFACTURING SYSTEMS
A filament drive mechanism (22, 122, 222, 322, 422, 500) comprising a rotatable component (36, 136, 236, 336, 436, 532) comprising a central hole (46, 146, 346, 446, 546) defined at least in part by an internally-threaded surface (48, 148, 348, 448, 548), and is configured to receive a filament strand (24) through the central hole (46, 146, 346, 446, 546) to engage the internally-threaded surface (48, 148, 348, 448, 548) with the filament strand (24). The filament drive mechanism (22, 122, 222, 322, 422, 500) further comprises at least one rotation mechanism (534) configured to rotate the rotatable component (36, 136, 236, 336, 436, 532), thereby allowing the engaged internally-threaded surface (48, 148, 348, 448, 548) to drive the filament strand (24) through the central hole (46, 146, 346, 446, 546) of the rotatable component (36, 136, 236, 336, 436, 532).
G06F 19/00 - Digital computing or data processing equipment or methods, specially adapted for specific applications (specially adapted for specific functions G06F 17/00;data processing systems or methods specially adapted for administrative, commercial, financial, managerial, supervisory or forecasting purposes G06Q;healthcare informatics G16H)
85.
LIQUEFIER ASSEMBLY FOR USE IN EXTRUSION-BASED DIGITAL MANUFACTURING SYSTEMS
A liquefier assembly (22, 322) comprising a liquefier tube (32, 123, 232, 332), where the liquefier tube (32, 123, 232, 332) comprises a sidewall (38, 138, 238, 338) having an inlet opening (40, 140, 240, 340) configured to receive a filament strand (24), an outlet opening (52), and a port (56, 156, 256) disposed through the sidewall (38, 138, 238, 338) at a location between the inlet opening (40, 140, 240, 340) and the outlet opening (52), the port (56, 156, 256) being configured to provide access for a filament drive mechanism (30) to engage with the received filament strand (24). The liquefier assembly (22, 322) further comprises a heat transfer component (34, 334) configured to generate a thermal gradient along a longitudinal length of the sidewall (38, 138, 238, 338) between the port (56, 156, 256) and the outlet opening (52).
B29C 41/02 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
86.
METHOD FOR BUILDING THREE-DIMENSIONAL OBJECTS CONTAINING EMBEDDED INSERTS
A method for generating build sequence data for a computer-aided design model (28, 64, 106, 138) of a three-dimensional object (44, 82), the method comprising identifying a location of an insert data representation (32, 68, 110, 142) in the computer-aided design model (28, 64, 106, 138), slicing the computer-aided design model (28, 64, 106, 138) into a plurality of sliced layers (36, 72, 112, 146), generating a plurality of support layers (38, 74, 114, 152) for at least a portion of the plurality of sliced layers (36, 72, 112, 146), and generating an unfilled region (40. 78, 116, 148) in the computer-aided design model (28, 64, 106, 138) at the identified location of the insert data representation (32, 68, 110, 142).
A system (10, 110, 210) for building a three-dimensional object (26, 126, 226) with a layer-based additive technique, the system (10, 110, 210) comprising a controller (16, 116, 216) configured to receive build sequence data for the three-dimensional object (26, 126, 226), a head assembly (18, 118, 218) in signal communication with the controller (16, 116, 216) and configured to form a plurality of layers (44, 304) of the three-dimensional object (26, 126, 226) based on the build sequence data, and an insert placement apparatus (22, 164, 280) in signal communication with the controller (16, 116, 216) and configured to place at least one insert (38, 138, 298) in the plurality of formed layers (44, 304) based on the build sequence data.
B29C 41/02 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
88.
METHOD FOR BUILDING AND USING THREE-DIMENSIONAL OBJECTS CONTAINING EMBEDDED IDENTIFICATION-TAG INSERTS
A method for building a three-dimensional object (28, 42, 58, 74, 80) containing an identification-tag insert (38, 54, 70, 78, 82), the method comprising performing a build operation to form layers (34, 48, 64) of the three-dimensional object (28, 42, 58, 74, 80) using a layer-based additive technique, placing the identification-tag insert (38, 54, 70, 78, 82) on at least a portion of the layers (34, 48, 64) during the build operation, and reading information from the identification-tag insert (38, 54, 70, 78, 82).
A consumable assembly (18, 118, 218, 318) comprising a container portion (34, 134, 234, 334) configured to retain a supply of filament (386), a guide tube (36, 136, 236, 336) connected to the container portion (34, 134, 234, 334), and a pump portion (38, 138, 238, 338) connected to the guide tube (36, 136, 236, 336).
G06F 19/00 - Digital computing or data processing equipment or methods, specially adapted for specific applications (specially adapted for specific functions G06F 17/00;data processing systems or methods specially adapted for administrative, commercial, financial, managerial, supervisory or forecasting purposes G06Q;healthcare informatics G16H)
90.
EXTRUSION HEAD FOR USE IN EXTRUSION-BASED LAYERED DEPOSITION SYSTEM
An extrusion head comprising at least one mounting structure, a first liquefier pump secured to the at least one mounting structure, a second liquefier pump disposed adjacent to the first liquefier pump, a toggle mechanism supported by the at least one mounting structure and configured to move the second liquefier pump relative to the first liquefier pump along a first axis, and a slot engagement assembly connected in part to the second liquefier pump for defining a range of motion for the second liquefier pump along the first axis.
B28B 13/00 - Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
91.
METHOD FOR BUILDING THREE-DIMENSIONAL OBJECTS WITH THIN-WALL REGIONS
A method for modifying a computer-aided design model of a three-dimensional object, the method comprising establishing a threshold wall width, providing at least one sliced layer polyline of the computer-aided design model, determining a first distance between first and second portions of the at least one sliced layer polyline, and adjusting locations of the first and second portion to provide a second distance if the first distance is less than the threshold wall width, where the second distance is about equal to the threshold wall width, or greater.
G06F 19/00 - Digital computing or data processing equipment or methods, specially adapted for specific applications (specially adapted for specific functions G06F 17/00;data processing systems or methods specially adapted for administrative, commercial, financial, managerial, supervisory or forecasting purposes G06Q;healthcare informatics G16H)
A tip cleaning assembly for use with an extrusion head of an extrusion-based layered deposition system includes a support component, a purge ledge assembly mounted on the support component, at least one set block mounted on the support component adjacent the purge ledge assembly, and at least one contact head removably mounted on the first set block, where the at least one contact head is configured to engage at least one extrusion tip of the extrusion head.
A syringe tip assembly (18) comprising a seal component (34) configured to engage a syringe tip (28), a nozzle (38) configured to slidably engage with the seal component (34), and a biasing member (36) configured to apply a biasing pressure between the seal component (34) and the nozzle (38).
A system for building a three-dimensional object based on build data representing the three-dimensional object, the system comprising an extrusion head configured to deposit a radiation-curable material in consecutive layers, where the radiation-curable material of each of the consecutive layers is in a self-supporting state, and a radiation source configured to selectively expose a portion of at least one of the consecutive layers to radiation in accordance with the build data.
A method for building a 3D object (18) with an extrusion-based layered deposition system comprising feeding a modified ABS material to an extrusion head (12) of the extrusion-based layered deposition system, melting the fed modified ABS material in the extrusion head (12) under conditions that improve a response time of the extrusion head (12), and depositing the molten thermoplastic material in a layer-by-layer manner to form the 3D object (18).
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
96.
VISCOSITY PUMP FOR EXTRUSION-BASED DEPOSITION SYSTEMS
A pump system (10) comprising a delivery assembly (22) configured to feed a solid material under operational power of a first drive motor (16), and a screw pump (24) comprising a housing (84) that at least partially defines a barrel (106) of the screw pump (10), an extrusion tip (82) secured to the housing (84) at a first end of the barrel (106), a liquefier (85, 342) secured to the housing (84) and intersecting with the barrel (106), and an impeller (94) extending at least partially through the barrel (106). The liquefier (85, 342) is configured to receive the solid material fed from the delivery assembly (22), to at least partially melt the received solid material, and to direct the at least partially melted material to the barrel (106), and the impeller (94) is configured to drive the at least partially melted material that is directed to the barrel (106) toward the extrusion tip (82) under operational power of a second drive motor (18).
B28B 17/00 - SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER - Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
97.
SURFACE-TREATMENT METHOD FOR RAPID-MANUFACTURED THREE-DIMENSIONAL OBJECTS
A method (10) for forming a surface-treated, three-dimensional object, comprising: solvent smoothing (16) an exterior surface of a rapid-manufactured, three-dimensional object, and media blasting (22) at least a portion of the solvent-smoothed exterior surface.
A method for building a three-dimensional object (10), the method includes positioning a metal part (16) within a build chamber of an extrusion-based layered deposition system, where the metal part (16) comprising a polymer-coated surface (24). The method also includes depositing a build material on the polymer-coated surface (24) of the metal part (16), wherein the deposited build material cools to form at least a portion of a layer (14) of the three-dimensional object (10).
G06F 19/00 - Digital computing or data processing equipment or methods, specially adapted for specific applications (specially adapted for specific functions G06F 17/00;data processing systems or methods specially adapted for administrative, commercial, financial, managerial, supervisory or forecasting purposes G06Q;healthcare informatics G16H)
99.
SINGLE-MOTOR EXTRUSION HEAD HAVING MULTIPLE EXTRUSION LINES
An extrusion head (20) comprising at least one drive wheel (51) and an assembly (50) positionable between at least a first state and a second state. The assembly (50) comprises a first extrusion line (58) configured to engage the at least one drive wheel (51) while the assembly is positioned in the first state, and a second extrusion line (60) configured to engage the at least one drive wheel (51) while the assembly (50) is positioned in the second state.
The present invention is a method for performing a calibration routine of a deposition device in a three-dimensional modeling machine that deposits a material to build up three-dimensional objects as directed by a controller on a substrate mounted on a platform. The method comprises generating a material build profile, which represents a three-dimensional structure at defined locations. A relative position of the material build profile is then determined. An expected build profile is identified and then compared to the determined relative position of the material build profile to identify any difference which represents an offset. The modeling system then positions the deposition device based upon the offset.
patents
