Abstract: A platen assembly for use with an extrusion-based 3D printer includes a grid assembly comprising at least a 4×2 framework of interlocked perpendicular x direction beams and y direction beams, providing a substantially planar upper surface and a bottom surface. The platen assembly includes a platen comprising a thin metal sheet supported on the upper surface of the grid assembly and secured to the grid assembly such that the top surface provides a substantially flat build surface. The x direction beams, the y direction beams and the platen are constructed of substantially a same thermal expansion properties, and wherein the build surface of the platen has a build surface area of at least 400 square inches and maintains its flatness to within a flatness tolerance of 0.020 inches over a temperature range of at least 20 C-300 C.

Abstract: A method of loading filament into a 3D printer that build parts by fused deposition modeling processes includes providing a 3D printer having a receptacle configured for accepting a plug-in connector from a filament supply. The method further includes providing a filament supply having a container configured to retain a supply of a filament, a filament guide tube having a length, an inlet end attached to the container and an outlet end, and a connector at the outlet end of the filament guide tube. The connector has a geometry allowing it to be plugged into the receptacle and comprises a conduit having an entrance for accepting the outlet end of the filament guide tube and an exit for passing the filament into the printer. The method includes causing a signal to be emitted proximate the receptacle such that when the plug-in connector is inserted into the receptable, light shines through the connector to inform the operator of a filament loading status.

Abstract: A platen assembly for use with an extrusion-based 3D printer includes a grid assembly comprising at least a 4×2 framework of interlocked perpendicular x direction beams and y direction beams, providing a substantially planar upper surface and a bottom surface. The platen assembly includes a platen comprising a thin metal sheet supported on the upper surface of the grid assembly and secured to the grid assembly such that the top surface provides a substantially flat build surface. The x direction beams, the y direction beams and the platen are constructed of substantially a same thermal expansion properties, and wherein the build surface of the platen has a build surface area of at least 400 square inches and maintains its flatness to within a flatness tolerance of 0.020 inches over a temperature range of at least 20 C-300 C.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system includes a liquefier tube compositionally comprising a metallic material, and having a first end and a second end offset along a longitudinal axis, and a flow channel extending from the first end to the second end. The assembly further includes an extrusion tip compositionally comprising a metallic material and coupled to the second end of the liquefier tube, the extrusion tip having a cavity having an interior shoulder wherein the cavity terminates in an opening. The liquefier includes a hardened insert compositionally comprising a material that is harder than the metallic material of the extrusion tip and the metallic material of the liquefier tube. The hardened insert has an exterior shoulder that engages the interior shoulder of the extrusion tip such that the insert is press fit within the extrusion tip.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system includes a liquefier tube compositionally comprising a metallic material, and having a first end and a second end offset along a longitudinal axis, and a flow channel extending from the first end to the second end. The assembly further includes an extrusion tip compositionally comprising a metallic material and coupled to the second end of the liquefier tube, the extrusion tip having a cavity having an interior shoulder wherein the cavity terminates in an opening. The liquefier includes a hardened insert compositionally comprising a material that is harder than the metallic material of the extrusion tip and the metallic material of the liquefier tube. The hardened insert has an exterior shoulder that engages the interior shoulder of the extrusion tip such that the insert is press fit within the extrusion tip.