Abstract: A filament drive for an extruder for an additive manufacturing system is provided. A drive gear is driven by a motor. A first driven gear is operably driven by the drive gear. A first hob has a toothed outer periphery connected to the first driven gear. A second driven gear is operably driven by the drive gear. A second hob has a toothed outer periphery connected to the second driven gear. The toothed outer peripheries of the first and second hobs define a filament receiving zone therebetween. A filament extruder including a heating element operated at greater than 48 volts may be provided.

Abstract: A filament straightener, an additive manufacturing machine including a filament straightener, and methods of straightening a filament are provided. The filament straightener includes abase member, a plurality of guide members attached to the base member. The plurality of guide members defines a filament flow path therebetween. The filament flow path extends between an inlet end and an outlet end. The guide members are spaced relative to the filament flow path to cause a filament passing along the filament flow path between the inlet end and the outlet end to experience a plurality of bends to remove curvature memory.

Abstract: A filament drive for an extruder for an additive manufacturing system is provided. A drive gear is driven by a motor. A first driven gear is operably driven by the drive gear. A first hob has a toothed outer periphery connected to the first driven gear. A second driven gear is operably driven by the drive gear. A second hob has a toothed outer periphery connected to the second driven gear. The toothed outer peripheries of the first and second hobs define a filament receiving zone therebetween. A filament extruder including a heating element operated at greater than 48 volts may be provided.

Abstract: An additive and subtractive manufacturing system and method of manufacturing is provided. The system includes a print bed and both an additive machine and a subtractive machine. The additive machine will dispense material onto the print bed and the additive machine will be able to perform subtractive manufacturing on the material dispensed onto the print bed. The additive machine and subtractive machine will be mounted to actuators for moving the machines in three-dimensions within a working zone adjacent the print bed. The system may include placement machines for placing pre-made components in the product during the manufacturing process.

Abstract: Couplings between driven shafts of an actuator and a motor of an actuator are provided. The coupling may be directly integrated into a rotor of the motor. The coupling may be provided by an adaptor that includes a shaft that extends into a central bore of the rotor of the motor. The adaptor can include a collar that defines a coupling recess that receives a distal end of the driven shaft of the actuator. The collar may take the form of a clamp.

Abstract: A linear guide including a guide rail, a carriage, a drive screw and a connection arrangement is provided. The guide rail defines a linear travel path. The carriage is mounted to the guide rail for motion along the linear travel path. The drive screw is operably mounted to the guide rail. The connection arrangement couples the drive screw to the carriage to convert rotary motion of the drive screw to linear actuation of the carriage along the linear travel path. The connection arrangement provides a single degree of linear freedom between the drive screw and the carriage in a direction that is generally perpendicular to the linear travel path. The single degree of linear freedom permits relative motion between the screw and the carriage to relieve internal binding between the relative components.

Abstract: Couplings between driven shafts of an actuator and a motor of an actuator are provided. The coupling may be directly integrated into a rotor of the motor. The coupling may be provided by an adaptor that includes a shaft that extends into a central bore of the rotor of the motor. The adaptor can include a collar that defines a coupling recess that receives a distal end of the driven shaft of the actuator. The collar may take the form of a clamp.

Abstract: A linear slide is provided. The linear slide includes a guide rail, a carriage arrangement and a drive mechanism. The carriage arrangement includes a sidecar or nut arrangement for engagement with a screw of the drive mechanism. The nut arrangement is laterally offset from a carriage of the carriage arrangement.

Abstract: A linear guide including a guide rail, a carriage, a drive screw and a connection arrangement is provided. The guide rail defines a linear travel path. The carriage is mounted to the guide rail for motion along the linear travel path. The drive screw is operably mounted to the guide rail. The connection arrangement couples the drive screw to the carriage to convert rotary motion of the drive screw to linear actuation of the carriage along the linear travel path. The connection arrangement provides a single degree of linear freedom between the drive screw and the carriage in a direction that is generally perpendicular to the linear travel path. The single degree of linear freedom permits relative motion between the screw and the carriage to relieve internal binding between the relative components.

Abstract: A linear slide is provided. The linear slide includes a guide rail, a carriage arrangement and a drive mechanism. The carriage arrangement includes a sidecar or nut arrangement for engagement with a screw of the drive mechanism. The nut arrangement is laterally offset from a carriage of the carriage arrangement.

Abstract: A guide rail is provided. The guide rail includes a base rail and a gear rack mounted to the base rail. The guide rail also provides at least one race upon which a guide roller can ride. The guide rail defines a reference point related to the raceway that has a parallelism relative to the gear rack of less than or equal to 0.005 inches per foot along the length of the guide rail. Preferably, the reference point is defined directly by the raceway and the parallelism is less than or equal to 0.001 inches per foot. A method of forming the guide rail is also provided. The method includes machining the reference point into the guide rail and using the reference point to locate machining a seat for mounting the gear rack. A guide assembly including a guide rail and a carriage or frame structure is also provided.

Abstract: A double door actuation system is provided. The actuation system includes a base frame, a drive motor, first and second guide rails and a pair of rail support arrangements. The drive motor is mounted to the base frame and includes a pinion gear rotatable about an axis of rotation. The guide rails include opposed raceways and a gear rack. The gear rack engages the pinion gear opposite sides such that the pinion gear simultaneously drives the guide rails in opposite directions parallel to a drive axis. The rail support arrangements are mounted to the base frame and support guide rails. The rail support arrangements maintain a substantially constant lateral location of the guide rails in a direction perpendicular to both the drive axis and axis of rotation to maintain a substantially constant mesh between the pinion the gear racks.