Abstract: A print head for additive manufacturing with a material includes an accumulator comprising an elongated body with an open interior and an inside diameter. A slide tube is slidably mounted within the open interior of the elongated body. The slide tube has a sealing piston head hermetically sealing the open end within the elongated body to define a variable gas containment space. A pressurized gas is supplied to the gas containment space. A rotatable shaping nozzle with an opening for discharging material is provided. A positive displacement extruder delivers material from the accumulator to the nozzle assembly. The nozzle assembly can include a nozzle rotation drive for rotating the shaping nozzle about an axis of rotation. The nozzle opening can be aligned with the axis of rotation, and defines a discharge axis that can be perpendicular to the axis of rotation. A method of additive manufacturing is also disclosed.

Abstract: A print head for additive manufacturing with a material includes an accumulator comprising an elongated body with an open interior and an inside diameter. A slide tube is slidably mounted within the open interior of the elongated body. The slide tube has a sealing piston head hermetically sealing the open end within the elongated body to define a variable gas containment space. A pressurized gas is supplied to the gas containment space. A rotatable shaping nozzle with an opening for discharging material is provided. A positive displacement extruder delivers material from the accumulator to the nozzle assembly. The nozzle assembly can include a nozzle rotation drive for rotating the shaping nozzle about an axis of rotation. The nozzle opening can be aligned with the axis of rotation, and defines a discharge axis that can be perpendicular to the axis of rotation. A method of additive manufacturing is also disclosed.

Abstract: A cable-driven additive manufacturing system includes an end effector configured for linear translation within a three-dimensional workspace, an aerial hoist suspending the end effector by at least one suspension cable, a plurality of base stations disposed below the aerial hoist, and control cables running from each of the base stations to the end effector.

Abstract: An additive manufacturing method that includes an extruder providing a supply of working material and a nozzle connected with respect to the extruder, the nozzle directing the working material to a deposit surface. A diverter valve is positioned between the extruder and the nozzle to direct the working material to an exhaust port away from the deposit surface under certain conditions.

Abstract: A method 100 for generating and dispensing a powdered 60 release agent during an additive manufacturing build is disclosed. A solid body 28 of release agent material is ground insitu by a grinder 50 and dispensed on a surface of the part 72 to prevent adhesion of an adjacent layer of a base material 70. With the addition of the powdered 60 release agent, a support structure 76 is easily separated from the base material 70 when the part 72 is complete, saving time and preventing the part 72 from sustaining unintentional damage. Since no powdered 60 release agent is actually loaded or stored in the apparatus 20, the potential for spillage, waste, inconsistent dispensing, inadvertent dispensing, and clumping due to humidity is eliminated.

Abstract: A cable-driven additive manufacturing system includes an end effector configured for linear translation within a three-dimensional workspace, an aerial hoist suspending the end effector by at least one suspension cable, a plurality of base stations disposed below the aerial hoist, and control cables running from each of the base stations to the end effector.

Abstract: An additive manufacturing method that includes an extruder providing a supply of working material and a nozzle connected with respect to the extruder, the nozzle directing the working material to a deposit surface. A diverter valve is positioned between the extruder and the nozzle to direct the working material to an exhaust port away from the deposit surface under certain conditions.

Abstract: An apparatus 20 and a method 100 for generating and dispensing a powdered 60 release agent during an additive manufacturing build is disclosed. A solid body 28 of release agent material is ground insitu by a grinder 50 and dispensed on a surface of the part 72 to prevent adhesion of an adjacent layer of a base material 70. With the addition of the powdered 60 release agent, a support structure 76 is easily separated from the base material 70 when the part 72 is complete, saving time and preventing the part 72 from sustaining unintentional damage. Since no powdered 60 release agent is actually loaded or stored in the apparatus 20, the potential for spillage, waste, inconsistent dispensing, inadvertent dispensing, and clumping due to humidity is eliminated.

Abstract: An apparatus 20 and a method 100 for generating and dispensing a powdered 60 release agent during an additive manufacturing build is disclosed. A solid body 28 of release agent material is ground insitu by a grinder 50 and dispensed on a surface of the part 72 to prevent adhesion of an adjacent layer of a base material 70. With the addition of the powdered 60 release agent, a support structure 76 is easily separated from the base material 70 when the part 72 is complete, saving time and preventing the part 72 from sustaining unintentional damage. Since no powdered 60 release agent is actually loaded or stored in the apparatus 20, the potential for spillage, waste, inconsistent dispensing, inadvertent dispensing, and clumping due to humidity is eliminated.

Abstract: A manufactured component, method and apparatus for advanced manufacturing that includes a polymeric working material formed into a mandrel with a carbon fiber overlay formed in a continuation of the process. The mandrel build and the carbon fiber overlay of the component preferably take place at atmospheric temperatures.

Abstract: An additive manufacturing extrusion head that includes a heated nozzle for accepting a feedstock and extruding the feedstock onto a substrate at a deposition plane, the nozzle having a longitudinal extrusion axis. A reciprocating platen surrounds the nozzle, the platen operable to reciprocate along the extrusion axis at or above the deposition plane as the nozzle extrudes feedstock onto the substrate; and wherein the platen flattens the extruded feedstock such that it does not protrude above the deposition plane as the extrusion head traverses over the substrate.

Abstract: An additive manufacturing extrusion head includes a nozzle for accepting and depositing a heated material onto a work surface and/or part. The nozzle includes a valve body and an internal poppet body moveable between positions to permit deposition of at least two bead sizes of heated material onto a work surface and/or part.

Abstract: An additive manufacturing machine includes a nozzle assembly with a noncircular, rotatable outlet. The nozzle assembly deposits a bead of material having a width that is defined by the angular orientation of the noncircular shaped outlet with respect to the material deposition path direction. The combination of high material deposition rate and fine resolution save time and energy while also producing high-quality parts.

Abstract: An apparatus 20 and a method 100 for generating and dispensing a powdered 60 release agent during an additive manufacturing build is disclosed. A solid body 28 of release agent material is ground insitu by a grinder 50 and dispensed on a surface of the part 72 to prevent adhesion of an adjacent layer of a base material 70. With the addition of the powdered 60 release agent, a support structure 76 is easily separated from the base material 70 when the part 72 is complete, saving time and preventing the part 72 from sustaining unintentional damage. Since no powdered 60 release agent is actually loaded or stored in the apparatus 20, the potential for spillage, waste, inconsistent dispensing, inadvertent dispensing, and clumping due to humidity is eliminated.

Abstract: Several examples of additive manufacturing machines and methods for depositing a bead of composite polymer material having continuous fiber reinforcement are disclosed. A length of fiber reinforcement is provided to a nozzle. The fiber reinforcement is embedded into a stream of a base polymer material at the nozzle and deposited as a bead of composite polymer material having fiber reinforcement. The fiber reinforcement may be dry or pre-impregnated with a reinforcing polymer. The additional strength of the composite polymer material having fiber reinforcement allows for true, three-dimensional printing of articles having unsupported regions.

Abstract: Several examples of an article of manufacture made with an additive manufacturing machine are disclosed. A length of fiber reinforcement is provided to a nozzle. The fiber reinforcement is embedded into a stream of a base polymer material at the nozzle and deposited as a bead of composite polymer material having fiber reinforcement. The fiber reinforcement may be dry or pre-impregnated with a reinforcing polymer. The additional strength of the composite polymer material having fiber reinforcement allows for true, three-dimensional printing of articles having unsupported regions.

Abstract: An additive manufacturing extrusion head includes a nozzle for accepting and depositing a heated material onto a work surface and/or part. The nozzle includes a valve body and an internal poppet body moveable between positions to permit deposition of at least two bead sizes of heated material onto a work surface and/or part.

Abstract: Hydraulic actuation systems having concentric chambers, variable displacements and energy recovery capabilities include cylinders with pistons disposed inside of barrels. When operating in energy consuming modes, high speed valves pressurize extension chambers or retraction chambers to provide enough force to meet or counteract an opposite load force. When operating in energy recovery modes, high speed valves return a working fluid from extension chambers or retraction chambers, which are pressurized by a load, to an accumulator for later use.

Abstract: Hydraulic actuation systems having variable displacements and energy recovery capabilities include cylinders with pistons disposed inside of barrels. When operating in energy consuming modes, high speed valves pressurize extension chambers or retraction chambers to provide enough force to meet or counteract an opposite load force. When operating in energy recovery modes, high speed valves return a working fluid from extension chambers or retraction chambers, which are pressurized by a load, to an accumulator for later use.

Abstract: A manufactured component, method and apparatus for advanced manufacturing that includes a polymeric working material formed into a mandrel with a carbon fiber overlay formed in a continuation of the process. The mandrel build and the carbon fiber overlay of the component preferably take place at atmospheric temperatures.