Abstract: There are provided techniques for direct printing material into parts made by additive manufacturing, such as parts made by laser sintering. The direct printed material may be a metal, elastomer, ceramic, or any other material. Further, the direct printed material is typically different than the laser sintering material. Other aspects of the invention include using direct printed materials in the laser sintered parts to improve part strength, provide multi-materials, selectively provide electrical conductivity, and/or provide other desirable features to the parts.

Abstract: In one aspect, methods of printing a color 3D article are described herein. In some embodiments, a method described herein comprises receiving data representing a surface colorization of the article, and transforming the data representing the surface colorization of the article into voxel data of the article. The voxel data comprises (a) location values and at least one of (b) color values and (c) transparency values for a plurality of columns of voxels normal or substantially normal to a surface of the article. The method further comprises selectively depositing layers of one or more build materials onto a substrate to form the article in accordance with the voxel data. In addition, at least one column of the plurality of columns of voxels exhibits a surface color resulting from a combination of colors of a plurality of voxels of the column.

Abstract: The invention is directed to systems and methods for detailing a graphical 3D solid model displayed to a user. An example system includes a graphical user interface device (e.g., joystick, keyboard, stylus, roller ball, touch screen, tablet, etc.) configured to receive input from a user and transmit the input to a computer including a Central Processing Unit (CPU) and/or a Graphics Processing Unit (GPU), a memory for use with the computer, and a video display configured to graphically display the detailed 3D solid model to the user.

Abstract: In one aspect, water removable compositions are described herein, including for use in various printing applications. In some embodiments, a composition described herein comprises 50-95% by weight alcohol wax having the formula CH3(CH2)nOH, wherein n is an integer from 15 to 40; 5-50% by weight tackifier; and 0.5-5% by weight colorant. In other instances, a composition described herein comprises 50-95% by weight carboxylic acid wax having the formula CH3(CH2)mCOOH, wherein m is an integer from 14 to 40; 5-50% by weight tackifier; and 0.5-5% by weight colorant. Additionally, in some cases, the tackifier of a composition described herein comprises a rosin acid, a rosin ester, a rosin alcohol, or a mixture or combination thereof. Further, the solubility of a colorant in a composition described herein can be characterized by a spectral strength delta value of 5% or less or 3% or less.

Abstract: There is provided improved laser sintering systems that increase the powder density and reduce anomalies of the powder layers that are sintered, that measure the laser power within the build chamber for automatic calibration during a build process, that deposit powder into the build chamber through a chute to minimize dusting, and that scrubs the air and cools the radiant heaters with recirculated scrubbed air. The improvements enable the laser sintering systems to make parts that are of higher and more consistent quality, precision, and strength, while enabling the user of the laser sintering systems to reuse greater proportions of previously used but unsintered powder.

Abstract: A composition and method of infiltrating an article of manufacture prepared by a laser sintering process is disclosed. The infiltration process maintains the dimensions and flexibility of the article, increases the strength of the article, and improves the physical and esthetic properties of the article.

Abstract: Methods of 3D printing an object with reduced curl on at least one surface that contacts a print plate are described herein. For example, in some embodiments, a method of 3D printing an object comprises depositing build material to form a first layer of a 3D printed object and depositing build material in a predetermined pattern to form a first layer of a skirt in contact with the 3D printed object. Depositing build material to form the first layer of the skirt comprises 3D printing a first layer of a sidewalk that substantially surrounds at least a portion of a perimeter of the 3D printed object and 3D printing a first layer of a perforated interface between the sidewalk and the perimeter of the skirt.

Abstract: In one aspect, methods of printing a 3D article are described herein. In some embodiments, a method of printing a 3D article comprises selectively depositing a first portion of build material in a fluid state onto a substrate to form a first region of build material; selectively depositing a first portion of support material in a fluid state to form a first region of support material; and selectively depositing a second portion of build material in a fluid state to form a second region of build material, wherein the first region of support material is disposed between the first region of build material and the second region of build material in a z-direction of the article. In some cases, the first region of support material forms a grayscale pattern and/or a CMY color pattern in combination with the first region of build material and/or the second region of build material.

Abstract: In one aspect, 3D printing systems for fabricating 3D soap objects are described herein. Such systems can form 3D soap objects from a particulate material and a fluid binder material based on design data, such as digital design data. In some cases, a 3D printing system comprises a build chamber comprising a build bed, a particulate material distribution device, and a fluid binder material dispenser. The particulate material distribution device can be configured to distribute successive layers of the particulate material on the build bed. The fluid binder material dispenser can be configured to selectively apply the fluid binder material to portions of the successive layers of particulate material in an amount sufficient to consolidate the portions to define cross-sectional portions of the object. In addition, the particulate material comprises a soap component in an amount of about 10 to 100% by weight.

Abstract: Systems and methods for construction of an instruction set for three-dimensional printing of a user-customizable image of a three-dimensional structure are provided. Methods can include receiving user input for customizing an image of a three-dimensional structure, control circuitry constructing an instruction set for the customized image of the three-dimensional structure, and control circuitry rendering the instruction set into a printable file usable by a three-dimensional printer.

Abstract: A fairing can be attached to a prosthetic limb or over a brace to alter the appearance of the prosthetic limb or brace. The outer surface of the prosthetic limb can be a mirror image of an intact limb and the outer surface of the brace can have an outer surface that corresponds to an injured limb. Because the fairing fits closely around the prosthetic limb or brace, the interior surface of the fairing has a surface that corresponds to a mirror image of an intact limb or an outer surface of an injured limb.

Abstract: In one aspect, adhesives for use with a 3D printer are described herein. In some embodiments, an adhesive for use with a 3D printer comprises a first polymeric component comprising a poly(vinyl alcohol) and a second polymeric component. The poly(vinyl alcohol), in some embodiments, comprises amorphous poly(vinyl alcohol). In some embodiments, the second polymeric component comprises a water-soluble polymer. Further, in some embodiments, an adhesive described herein further comprises a solvent, a surfactant, and/or a preservative.

Abstract: A system is provided for creating a preview embossed mesh for graphical display to a user. The system includes a graphical user interface device and a computer, which includes a Graphics Processing Unit (GPU) and a Central Processing Unit (CPU). A memory for use with the computer is configured to (a) determine a 3D volumetric mask, (b) determine a distance map corresponding to the 3D volumetric mask, and (c) render offset geometry. The GPU is used to compute the distance map within the 3D volumetric mask. The distance map and the 3D volumetric mask are accessible by a shader to provide a preview embossed mesh for graphical display. The system also includes a video display to graphically display the preview embossed mesh to the user.

Abstract: In one aspect, methods of printing a three-dimensional article are described herein. In some embodiments, a method described herein comprises jetting an ink at a temperature T1 onto a substrate at a temperature T2 to form a layer of the ink on the substrate. The method further comprises subsequently curing the layer of the ink. In some embodiments, T1 is greater than T2 and the ink in an uncured state has a liquid-gel transition temperature below T1 and above T2. Further, the layer of the ink is deposited on the substrate at a rate R1 in mg/s/in2 that is within 60% of a gelation rate R2 of the ink in inverse minutes in an uncured state at T2. The ink can comprise a curable material and a gellant.

Abstract: In one aspect, water removable compositions are described herein, including for use in various printing applications. In some embodiments, a composition described herein comprises 50-95% by weight alcohol wax having the formula CH3(CH2)nOH, wherein n is an integer from 15 to 40; 5-50% by weight tackifier; and 0.5-5% by weight colorant. In other instances, a composition described herein comprises 50-95% by weight carboxylic acid wax having the formula CH3(CH2)mCOOH, wherein m is an integer from 14 to 40; 5-50% by weight tackifier; and 0.5-5% by weight colorant. Additionally, in some cases, the tackifier of a composition described herein comprises a rosin acid, a rosin ester, a rosin alcohol, or a mixture or combination thereof. Further, the solubility of a colorant in a composition described herein can be characterized by a spectral strength delta value of 5% or less or 3% or less.

Abstract: In one aspect, inks for use with a three dimensional printing system are described herein. In some embodiments, an ink for use in a three dimensional printing system comprises about 10-95 weight % polymerizable component and about 3-25 weight % non-reactive wax component, wherein the ink when cured has a Tg greater than the melting point of the non-reactive wax component.

Abstract: In one aspect, composite build materials for use with a 3D printing system are described herein. In some embodiments, a composite build material described herein comprises a carrier ink comprising a curable material; and pigment particles dispersed in the carrier ink, wherein the pigment particles comprise mica. In some cases, the carrier ink is present in the composite build material in an amount of about 80-98% by weight, and the curable material comprises one or more species of monomeric and/or oligomeric (meth)acrylates. Additionally, in some instances, the pigment particles are present in the composite build material in an amount of about 2-8% by weight and comprise up to about 85% by weight mica, based on the total weight of the pigment particles. The pigment particles, in some cases, can also comprise TiO2 and/or Fe2O3.

Abstract: Powder compositions and articles and methods of forming articles from powder compositions are provided. The powder compositions include at least one powder that preferably includes an amount of one or more branched polymers such as, for example, one or more branched polyamide polymers. The powder composition is preferably capable of being formed, via a layer-by-layer sintering process such as, for example, selective laser sintering, into a three-dimensional article.

Abstract: In one aspect, build materials operable for use in 3D printing systems are described herein. In some embodiments, a build material comprises an oligomeric curable material, a reactive component that is solid at 25° C., and at least one diluent, wherein the reactive component comprises at least one chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material and/or the at least one diluent.

Abstract: Powder compositions and articles and methods of forming articles from powder compositions are provided. In one embodiment the powder compositions include at least one polyester polymer powder and an amount of reinforcing particles having an aspect ratio of preferably at least about 5:1. In another embodiment the powder compositions include at least one medium-high melting temperature, aromatic and crystalline polyester polymer powder. In a preferred embodiment, the powder composition is capable of being formed, via a laser sintering process, into a three-dimensional article that exhibits one or more desirable mechanical properties in an elevated temperature environment.