Abstract: A machine for producing additive printed parts having a print head attached to a gantry, including a frame having a plurality of side walls that define an interior space, a build table positioned within the interior space and including a print bed for supporting the additive printed part, a plurality of bellows attached at a first end to the gantry and at a second end to at least one of the plurality of side walls, a build volume defined by the plurality of side walls, the plurality of bellows and the build table, and an infrared heater disposed on the build table for heating an additive printed part positioned on the build table.

Abstract: An X-arm carriage assembly for an additive manufacturing machine includes a magnet frame, a frame plate, a top plate and a bottom plate that define a rectangular shaped tube structure, first and second support brackets attached to first and second distal ends of the rectangular shaped tube structure to support the X-arm carriage assembly for movement along an x-axis, an encoder strip, a top linear rail mounted and a bottom linear rail adapted to moveably support a print head carriage on the X-arm carriage assembly along a y-axis, a longitudinal slot formed within the magnet frame, and a linear motor magnet track mounted onto the magnet frame in alignment with the longitudinal slot and extending longitudinally along the magnet frame, the linear motor magnet track including one of a single magnet and a plurality of magnets mounted adjacent one another.

Abstract: A machine for manufacturing additive printed parts includes a first filament cartridge adapted to support a length of filament of a material from which the additive printed parts will be manufactured, a print head moveably supported within the machine, and a first filament buffer positioned between the first filament cartridge and the print head and including a first buffer volume. The filament supported within the first filament cartridge extends from the first filament cartridge, through the first filament buffer, and to the print head and is allowed to deflect within the first buffer volume.

Abstract: A three-dimensional printer head includes a drive motor, the drive motor including a drive shaft, a feed plate is affixed to the drive motor, and a feed hob is mounted to the drive shaft. The feed hob includes drive teeth configured to engage a filament. An idle assembly mounted to the feed plate configured to bias the filament against the drive teeth. The printer head further includes a z-axis plate assembly, wherein the z-axis plate assembly includes at least two flexures coupling a z-axis plate to the feed plate and a print nozzle mounted to the z-axis plate assembly. The printer head also includes a sensor coupled to the feed plate, wherein the sensor is configured to be triggered by the z-axis plate assembly when the z-axis plate assembly moves a given distance in a first direction.

Abstract: A method for receiving and dispensing a 3D printer filament includes receiving the 3D printer filament using a nozzle having a barrel and an end tip. The barrel includes an internal bore, an exterior surface and a heat break defined in the exterior surface of the barrel. The internal bore has a filament receiving end and a filament discharge end, the end tip being positioned proximate to the filament discharge end. The method includes heating the 3D printer filament with a heating element proximate the filament discharge end, where the heating element includes a heating wire wrapped around the exterior surface of the barrel. The method also includes dispensing the 3D printer filament through a discharge orifice of the end tip.

Abstract: A split spool assembly for discharging filament to a three-dimensional printer is provided. The assembly includes a first spool part having a first reel collar angularly spaced from an axis and a first hub portion, which is disposed about the axis and angularly spaced from the first reel collar. The assembly further includes a second spool part having a second reel collar angularly spaced from the axis and a second hub portion, which is disposed about the axis and angularly spaced from the second reel collar. The first and second collars are spaced from one another for storing a predetermined amount of filament therebetween. The first and second hub portions are disposed about the axis and terminate at associated first and second ends, with the first and second ends being positioned adjacent to one another such that the first and second hub portions are arranged in series along the axis.

Abstract: A Z-Stage assembly for an additive manufacturing machine includes a Z-frame adapted to support a build table within an additive manufacturing machine, a first support element adapted to support the Z-frame, the first support element adapted to control the position of the Z-frame along an x-axis, a y-axis and a z-axis, a second support element adapted to support the Z-frame, the second support element adapted to control the position of the Z-frame along only the z-axis, and a third support element adapted to support the Z-frame, the third support element adapted to control the position of the Z-frame along the y-axis and the z-axis, wherein, each of the first, second and third support elements are adapted to selectively and independently move the Z-frame along the z-axis and to independently allow pivotal motion of the Z-frame relative to the first, second and third support elements.

Abstract: A modular three-dimensional printer frame including a z-stage frame adapted to support a build platform, a damper frame connected to the z-stage frame adapted to support a print head, a mount arranged between the z-stage frame and the damper frame, and a damper arranged between the z-stage frame and the damper frame. The damper frame is mounted to the z-stage frame by arranging a first damper between a damper frame to a z-stage frame; arranging a first mount between the damper frame and the z-stage frame; and aligning the damper frame and the z-stage frame with the first mount.

Abstract: A nozzle is configured for receiving and dispensing a 3D printer filament. The nozzle includes a barrel, a heating element, and an end tip. The barrel has an internal bore and an exterior surface. The internal bore has a filament receiving end and a filament discharge end. A heat break is defined in the exterior surface of the barrel. The heating element is proximate the filament discharge end. The heating element includes a heating wire wrapped around the exterior surface of the barrel. The end tip is proximate the filament discharge end. The 3D filament is received in the filament receiving end heated by the heating element and dispensed through end tip proximate the filament discharge end.

Abstract: A filament container for housing a spool of filament comprising a base and a lid that define an inner volume. The lid rotatably attached to the base and moveable between a closed position, wherein the inner volume is substantially sealed, and an open position, wherein the inner volume is accessible. First and second horizontal shafts are supported rotatably within the inner volume, parallel to and spaced from one another a distance, and rotatable about a respective longitudinal axis. The first and second horizontal shafts are adapted to support a spool of filament vertically within the inner volume and to allow the spool of filament to freely rotate about a horizontal axis that is parallel to and spaced from the longitudinal axis of each of the first and second horizontal shafts as filament is pulled from the spool and out of the filament container.

Abstract: A machine for manufacturing additive printed parts includes a first filament cartridge adapted to support a length of filament of a material from which the additive printed parts will be manufactured, a print head moveably supported within the machine, and a first filament buffer positioned between the first filament cartridge and the print head and including a first buffer volume. The filament supported within the first filament cartridge extends from the first filament cartridge, through the first filament buffer, and to the print head and is allowed to deflect within the first buffer volume.

Abstract: An X-arm carriage assembly for an additive manufacturing machine includes a magnet frame, a frame plate, a top plate and a bottom plate that define a rectangular shaped tube structure, first and second support brackets attached to first and second distal ends of the rectangular shaped tube structure to support the X-arm carriage assembly for movement along an x-axis, an encoder strip, a top linear rail mounted and a bottom linear rail adapted to moveably support a print head carriage on the X-arm carriage assembly along a y-axis, a longitudinal slot formed within the magnet frame, and a linear motor magnet track mounted onto the magnet frame in alignment with the longitudinal slot and extending longitudinally along the magnet frame, the linear motor magnet track including one of a single magnet and a plurality of magnets mounted adjacent one another.

Abstract: A filament container for housing a spool of filament comprising a base and a lid that define an inner volume. The lid rotatably attached to the base and moveable between a closed position, wherein the inner volume is substantially sealed, and an open position, wherein the inner volume is accessible. First and second horizontal shafts are supported rotatably within the inner volume, parallel to and spaced from one another a distance, and rotatable about a respective longitudinal axis. The first and second horizontal shafts are adapted to support a spool of filament vertically within the inner volume and to allow the spool of filament to freely rotate about a horizontal axis that is parallel to and spaced from the longitudinal axis of each of the first and second horizontal shafts as filament is pulled from the spool and out of the filament container.

Abstract: A machine for producing additive printed parts having a print head attached to a gantry, including a frame having a plurality of side walls that define an interior space, a build table positioned within the interior space and including a print bed for supporting the additive printed part, a plurality of bellows attached at a first end to the gantry and at a second end to at least one of the plurality of side walls, a build volume defined by the plurality of side walls, the plurality of bellows and the build table, and an infrared heater disposed on the build table for heating an additive printed part positioned on the build table.

Abstract: A three-dimensional printer head includes a drive motor, the drive motor including a drive shaft, a feed plate is affixed to the drive motor, and a feed hob is mounted to the drive shaft. The feed hob includes drive teeth configured to engage a filament. An idle assembly mounted to the feed plate configured to bias the filament against the drive teeth. The printer head further includes a z-axis plate assembly, wherein the z-axis plate assembly includes at least two flexures coupling a z-axis plate to the feed plate and a print nozzle mounted to the z-axis plate assembly. The printer head also includes a sensor coupled to the feed plate, wherein the sensor is configured to be triggered by the z-axis plate assembly when the z-axis plate assembly moves a given distance in a first direction.

Abstract: A three-dimensional printer head includes a drive motor, the drive motor including a drive shaft, a feed plate is affixed to the drive motor, and a feed hob is mounted to the drive shaft. The feed hob includes drive teeth configured to engage a filament. An idle assembly mounted to the feed plate configured to bias the filament against the drive teeth. The printer head further includes a z-axis plate assembly, wherein the z-axis plate assembly includes at least two flexures coupling a z-axis plate to the feed plate and a print nozzle mounted to the z-axis plate assembly. The printer head also includes a sensor coupled to the feed plate, wherein the sensor is configured to be triggered by the z-axis plate assembly when the z-axis plate assembly moves a given distance in a first direction.

Abstract: A machine for manufacturing additive printed parts includes a first filament cartridge adapted to support a length of filament of a material from which the additive printed parts will be manufactured, a print head moveably supported within the machine, and a first filament buffer positioned between the first filament cartridge and the print head and including a first buffer volume. The filament supported within the first filament cartridge extends from the first filament cartridge, through the first filament buffer, and to the print head and is allowed to deflect within the first buffer volume.

Abstract: A three-dimensional printer and a method of printing includes feeding a feedstock into a print nozzle including a heated barrel by applying a first extrusion force on the feedstock with a feed system; heating the feedstock in the heated barrel at a first temperature to melt the feedstock; and depositing the melted feedstock onto a support table, wherein the first extrusion force and first temperature are selected to provide a volumetric flow rate in the range of up to 120 cubic millimeters per second.