Abstract: An additively manufactured structure and methods for making and using same. In a method for making the structure, the structure can be printed using a single bead, according to a single toolpath, according to an open toolpath, or a combination thereof. Advantageously, printing efficiency can be improved. Geometry, size and/or shape of the structure can be selected with more flexibility. An exemplary method can form an overhang without using an infill or a support structure. Furthermore, the overhang can be formed accurately in an easy manner without a need of accurate positioning of the infill or the support structure. The printing process can be simplified. An alternative exemplary method can form a wall section that terminates by connecting to another wall section. Advantageously, the wall sections can be strong because of the mutual support and appearance of the terminated wall section can be improved.

Abstract: Methods and apparatus for additive manufacturing. In a method for additive manufacturing, a build sheet can be positioned on a print substrate of a printer. An object can be printed on the build sheet. The object can be detached from the build sheet. Advantageously, the build sheet can prevent the object from shifting on the build sheet during printing. Removing the build sheet from the object does not result in significant deformation or bending of the object. Damage to the object can be prevented. The object does not require additional cleaning or finishing for removing any residual or material. The build sheet can be ready for reuse. The build sheet can advantageously have mechanical strength to sustain removal of the build sheet from the object.

Abstract: An additively manufactured structure and methods for making and using same. An object can be printed at least partially on an attachment portion. The attachment portion can be bonded to the object upon the printing. The object does not need to be removed from the attachment portion. The need of providing a print surface to allow easy removal of the object is eliminated. The object can be a flat panel and can eliminate the need of printing a large flat layer using additive manufacturing. The attachment portion can be cut prior to the printing, so no trimming needs to be performed after the printing. The attachment portion can be made of a material that has one or more selected properties to expand functionalities of the object. A secondary operation for attaching the attachment portion to the object after the printing can be eliminated.

Abstract: An additive manufactured structure and methods for making and using same. The structure includes a plurality of layers stacked in a stacking direction. The structure further includes at least one reinforcement structure affixed to the layers and extending at least partially in the stacking direction. The reinforcement structure can hold the layers together to stiffen and strengthen the structure. Mechanical strength of the structure in the stacking direction can advantageously be improved. Shape and spatial distribution of the reinforcement structure can be customized and adapted to the geometry of the layers to enhance strengthening effect. The reinforcement structure can be tension free or have a compressive stress induced by a preload applied during manufacturing. The compressive stress can be adjusted dynamically via a sensor. The structure and methods provide, among other things, novelty for addressing the inherent weaknesses in parts created by large-scale extrusion deposition processes.

Abstract: An additively manufactured structure and methods for making and using same. In a method for making the structure, a first layer structure can be formed. A second layer structure can be formed on the first layer structure and a support structure. The support structure can be removed from the second layer structure. The second layer structure can include an overhang structure that does not deform or break after the support structure is removed. The support structure can provide support to the second layer structure during printing. Strong bridging capability of the second layer structure is not required. The support structure can be quick and easy to make. The support structure can be reusable and does not add weight to the printed structure. The support structure can be easily removed after completing of printing. Installation of the support structure can be fast without significantly interfering with printing process.

Abstract: A system for part location and long-range scanning of large additively manufactured structures and method for using the same. In some embodiments, the method for locating and scanning a three-dimensional (3D) object comprises scanning a first portion of the 3D object from a first position via a long-range scanner on a mobile platform, determining whether additional portions of the 3D object require scanning, moving the long-range scanner via the mobile platform to a second position based on said determination that additional portions of the 3D object require scanning, and aligning each portion of the scanned 3D object.

Abstract: An additive manufactured structure and methods for making and using same. The structure includes a plurality of layers stacked in a stacking direction. The structure further includes at least one reinforcement structure affixed to the layers and extending at least partially in the stacking direction. The reinforcement structure can hold the layers together to stiffen and strengthen the structure. Mechanical strength of the structure in the stacking direction can advantageously be improved. Shape and spatial distribution of the reinforcement structure can be customized and adapted to the geometry of the layers to enhance strengthening effect. The reinforcement structure can be tension free or have a compressive stress induced by a preload applied during manufacturing. The compressive stress can be adjusted dynamically via a sensor. The structure and methods provide, among other things, a novel means for addressing the inherent weaknesses in parts created by large-scale extrusion deposition processes.

Abstract: An additive manufactured structure and methods for making and using same. The structure includes a plurality of layers stacked in a stacking direction. The structure further includes at least one reinforcement structure affixed to the layers and extending at least partially in the stacking direction. The reinforcement structure can hold the layers together to stiffen and strengthen the structure. Mechanical strength of the structure in the stacking direction can advantageously be improved. Shape and spatial distribution of the reinforcement structure can be customized and adapted to the geometry of the layers to enhance strengthening effect. The reinforcement structure can be tension free or have a compressive stress induced by a preload applied during manufacturing. The compressive stress can be adjusted dynamically via a sensor. The structure and methods provide, among other things, a novel means for addressing the inherent weaknesses in parts created by large-scale extrusion deposition processes.

Abstract: An additively manufactured structure and methods for making and using same. In a method for making the structure, the structure can be printed using a single bead, according to a single toolpath, according to an open toolpath, or a combination thereof. Advantageously, printing efficiency can be improved. Geometry, size and/or shape of the structure can be selected with more flexibility. An exemplary method can form an overhang without using an infill or a support structure. Furthermore, the overhang can be formed accurately in an easy manner without a need of accurate positioning of the infill or the support structure. The printing process can be simplified. An alternative exemplary method can form a wall section that terminates by connecting to another wall section. Advantageously, the wall sections can be strong because of the mutual support and appearance of the terminated wall section can be improved.

Abstract: An additively manufactured structure and methods for making and using same. An object can be printed at least partially on an attachment portion. The attachment portion can be bonded to the object upon the printing. The object does not need to be removed from the attachment portion. The need of providing a print surface to allow easy removal of the object is eliminated. The object can be a flat panel and can eliminate the need of printing a large flat layer using additive manufacturing. The attachment portion can be cut prior to the printing, so no trimming needs to be performed after the printing. The attachment portion can be made of a material that has one or more selected properties to expand functionalities of the object. A secondary operation for attaching the attachment portion to the object after the printing can be eliminated.

Abstract: Methods and apparatus for additive manufacturing. In a method for additive manufacturing, a build sheet can be positioned on a print substrate of a printer. An object can be printed on the build sheet. The object can be detached from the build sheet. Advantageously, the build sheet can prevent the object from shifting on the build sheet during printing. Removing the build sheet from the object does not result in significant deformation or bending of the object. Damage to the object can be prevented. The object does not require additional cleaning or finishing for removing any residual or material. The build sheet can be ready for reuse. The build sheet can advantageously have mechanical strength to sustain removal of the build sheet from the object.

Abstract: A system for part location and long-range scanning of large additively manufactured structures and method for using the same. In some embodiments, the method for locating and scanning a three-dimensional (3D) object comprises scanning a first portion of the 3D object from a first position via a long-range scanner on a mobile platform, determining whether additional portions of the 3D object require scanning, moving the long-range scanner via the mobile platform to a second position based on said determination that additional portions of the 3D object require scanning, and aligning each portion of the scanned 3D object.

Abstract: An additively manufactured structure and methods for making and using same. In a method for making the structure, a first layer structure can be formed. A second layer structure can be formed on the first layer structure and a support structure. The support structure can be removed from the second layer structure. The second layer structure can include an overhang structure that does not deform or break after the support structure is removed. The support structure can provide support to the second layer structure during printing. Strong bridging capability of the second layer structure is not required. The support structure can be quick and easy to make. The support structure can be reusable and does not add weight to the printed structure. The support structure can be easily removed after completing of printing. Installation of the support structure can be fast without significantly interfering with printing process.

Abstract: An additive manufactured structure and methods for making and using same. The structure includes a plurality of layers stacked in a stacking direction. The structure further includes at least one reinforcement structure affixed to the layers and extending at least partially in the stacking direction. The reinforcement structure can hold the layers together to stiffen and strengthen the structure. Mechanical strength of the structure in the stacking direction can advantageously be improved. Shape and spatial distribution of the reinforcement structure can be customized and adapted to the geometry of the layers to enhance strengthening effect. The reinforcement structure can be tension free or have a compressive stress induced by a preload applied during manufacturing. The compressive stress can be adjusted dynamically via a sensor. The structure and methods provide, among other things, a novel means for addressing the inherent weaknesses in parts created by large-scale extrusion deposition processes.