Abstract: Disclosed are systems, devices, and methods for additive manufacturing that allow for control of composition and/or porosity of components being manufactured. More particularly, in exemplary embodiments, a secondary material can be used in conjunction with a primary feedstock material in a spatially controlled manner during an additive manufacturing process to control a composition of materials and/or porosity of a manufactured component. Systems, devices, and methods for additive manufacturing are also disclosed that allow for control of a pressure of an atmosphere surrounding a build surface during an additive manufacturing process. More particularly, a pressure of an atmosphere surrounding a build surface can be raised to a pressure greater than standard atmospheric pressure. Various features of the exemplary embodiments of the systems, devices, and methods disclosed can be used together to further control for composition and/or porosity and quality of a manufactured part.

Abstract: Methods, systems, and devices for precision locating additively manufactured components for assembly and/or post processing manufacturing are provided for herein. In some embodiments, at least one component can be additively manufactured to include one or more kinematic features on one or more surfaces of the component. The kinematic feature(s) can be configured to engage complementary kinematic feature(s) formed in a second component so the two components can form an assembly. Alternatively, the kinematic feature(s) can be configured to engage complementary kinematic feature(s) associated with a post-processing machine such that the one or more post-processing actions can be performed on the component after the component is precisely located with respect to the machine by way of the kinematic features of the component and associated with the machine. A variety of systems and methods that utilize kinematic features are also provided.

Abstract: The present invention provides methods for uniform growth of nanostructures such as nanotubes (e.g., carbon nanotubes) on the surface of a substrate, wherein the long axes of the nanostructures may be substantially aligned. The nanostructures may be further processed for use in various applications, such as composite materials. For example, a set of aligned nanostructures may be formed and transferred, either in bulk or to another surface, to another material to enhance the properties of the material. In some cases, the nanostructures may enhance the mechanical properties of a material, for example, providing mechanical reinforcement at an interface between two materials or plies. In some cases, the nanostructures may enhance thermal and/or electronic properties of a material. The present invention also provides systems and methods for growth of nanostructures, including batch processes and continuous processes.

Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.

Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.

Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.

Abstract: A variety of additive manufacturing techniques can be adapted to fabricate a substantially net shape object from a computerized model using materials that can be debound and sintered into a fully dense metallic part or the like. However, during sintering, the net shape will shrink as binder escapes and the base material fuses into a dense final part. If the foundation beneath the object does not shrink in a corresponding fashion, the resulting stresses throughout the object can lead to fracturing, warping or other physical damage to the object resulting in a failed fabrication. To address this issue, a variety of techniques are disclosed for substrates and build plates that contract in a manner complementary to the object during debinding and sintering.

Abstract: Certain example embodiments of this invention relate to methods for large area graphene precipitation onto glass, and associated articles/devices. For example, a coated article including a graphene-inclusive film on a substrate, and/or a method of making the same, is provided. A metal-inclusive catalyst layer (e.g., of or including Ni and/or the like) is disposed on the substrate. The substrate with the catalyst layer thereon is exposed to a precursor gas and a strain-inducing gas at a temperature of no more than 900 degrees C. Graphene is formed and/or allowed to form both over and contacting the catalyst layer, and between the substrate and the catalyst layer, in making the coated article. The catalyst layer, together with graphene formed thereon, is removed, e.g., through excessive strain introduced into the catalyst layer as associated with the graphene formation. Products including such articles, and/or methods of making the same, also are contemplated herein.

Abstract: Systems, devices, and methods for printing on surfaces of three-dimensional objects are provided. The systems, devices, and methods allow for images, and three-dimensional structures, to be printed onto a surface of a three-dimensional object. The surface of the three-dimensional object can have many different shapes, including an arbitrary or non-uniform shape having multiple curves. In one exemplary embodiment, the method includes associating a pattern of polygons with a surface of a three-dimensional object and then scaling a pattern of polygons associated with an image to be printed onto the surface with the pattern of polygons associated with the surface. One or more polygons of the scaled pattern of polygons are then progressively projected onto the surface, and a photosensitive material associated with the surface is cured to set projected image portion on the surface. Systems, devices, and other methods for printing onto surfaces of three-dimensional objects are also provided.

Abstract: The present invention provides methods for uniform growth of nanostructures such as nanotubes (e.g., carbon nanotubes) on the surface of a substrate, wherein the long axes of the nanostructures may be substantially aligned. The nanostructures may be further processed for use in various applications, such as composite materials. For example, a set of aligned nanostructures may be formed and transferred, either in bulk or to another surface, to another material to enhance the properties of the material. In some cases, the nanostructures may enhance the mechanical properties of a material, for example, providing mechanical reinforcement at an interface between two materials or plies. In some cases, the nanostructures may enhance thermal and/or electronic properties of a material. The present invention also provides systems and methods for growth of nanostructures, including batch processes and continuous processes.

Abstract: Controllable electromechanical adhesive devices including three-dimensional dielectrically-coated microstructures that are mechanically compliant are provided. The microstructures can be controlled to provide tunable electromechanical surface adhesion, allowing for dexterous gripping of microscale and/or macroscale objects. For example, the devices can tune the surface adhesion strength of one or more microstructures without complex mechanical actuation in a wide range of on/off ratios with low voltage. The devices can be configured as a force sensor capable of providing tactile feedback for determining the load applied against the microstructures by the surface of an object. For example, the devices can provide output indicative of changes in an electrical property of one or more microstructures for determining the applied load of an object. The devices can be pixelated or otherwise configured to provide localized force sensing and/or surface adhesion.

Abstract: Disclosed are methods for building colloidal solids by precipitation from a liquid bridge using a needle through which a colloidal particle suspension is dispensed onto a substrate in a temperature-controlled environment. The substrate can rest on a motion-controlled stage, and freeform shapes can be built by coordinating the motion of the stage with the rate of dispense of colloidal particle suspension. Aspects include a scaling law that governs the rate of assembly and a direct-write colloidal assembly process that combines self-assembly with direct-write 3D printing, and can be used to build exemplary freestanding structures using a diverse materials, such as polystyrene, silica and gold particles. Additionally, disclosed are methods for predicting and eliminating cracking by a geometric relationship between particle size and structure dimensions, enabling the production of macroscale, crack-free colloidal crystals.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is fabricated between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. Interface layers suitable for manufacture with an additive manufacturing system may resist the formation of bonds between a support structure and an object during subsequent sintering processes.

Abstract: Systems, devices, and methods for printing on surfaces of three-dimensional objects are provided. The systems, devices, and methods allow for images, and three-dimensional structures, to be printed onto a surface of a three-dimensional object. The surface of the three-dimensional object can have many different shapes, including an arbitrary or non-uniform shape having multiple curves. In one exemplary embodiment, the method includes associating a pattern of polygons with a surface of a three-dimensional object and then scaling a pattern of polygons associated with an image to be printed onto the surface with the pattern of polygons associated with the surface. One or more polygons of the scaled pattern of polygons are then progressively projected onto the surface, and a photosensitive material associated with the surface is cured to set projected image portion on the surface. Systems, devices, and other methods for printing onto surfaces of three-dimensional objects are also provided.

Abstract: The present disclosure is directed to the creation and/or manipulation of microfluidic systems and methods that can be formed in pre-existing modular blocks. Microfluidic paths can be formed in one or more blocks, and when multiple blocks are used, the blocks can be used together to form a path across the blocks. The paths can be sealed to prevent fluid leakage. The modular blocks can be readily available blocks which can then be individually customized to achieve various microfluidic design goals. The paths can be formed in outer surfaces of the blocks and/or disposed through a volume of the blocks. The modular blocks can have a uniform design across various block types, making it easy to reconfigure systems and/or remove and replace blocks and other components of the system. Methods for constructing such systems, and using such systems, are also provided.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. The support structure may be a multi-part support structure to mitigate mold lock or facilitate removal from enclosed spaces.

Abstract: Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.

Abstract: Systems, devices, and methods for additive manufacturing are provided that allow for components being manufactured to be assessed during the printing process. As a result, changes to a print plan can be considered, made, and implemented during the printing process. More particularly, in exemplary embodiments, a spectrometer is operated while a component is being printed to measure one or more parameters associated with one or more layers of the component being printed. The measured parameter(s) are then relied upon to determine if any changes are needed to the way printing is occurring, and if such changes are desirable, the system is able to implement such changes during the printing process. By way of non-limiting examples, printed material in one or more layers may be reheated to alter the printed component, such as to remove defects identified by the spectrometer data.

Abstract: The present invention provides methods for uniform growth of nanostructures such as nanotubes (e.g., carbon nanotubes) on the surface of a substrate, wherein the long axes of the nanostructures may be substantially aligned. The nanostructures may be further processed for use in various applications, such as composite materials. For example, a set of aligned nanostructures may be formed and transferred, either in bulk or to another surface, to another material to enhance the properties of the material. In some cases, the nanostructures may enhance the mechanical properties of a material, for example, providing mechanical reinforcement at an interface between two materials or plies. In some cases, the nanostructures may enhance thermal and/or electronic properties of a material. The present invention also provides systems and methods for growth of nanostructures, including batch processes and continuous processes.

Abstract: A printer fabricates an object from a computerized model using a fused filament fabrication process. The shape of an extrusion nozzle may be varied during extrusion to control, e.g., an amount of build material deposited, a shape of extrudate exiting the nozzle, a feature resolution, and the like.