Abstract: Methods for producing 3D printing composite polymer materials for use in additive manufacturing processes are provided. The methods result in enhancing the material properties of the printing material by providing a uniform and smooth surface finish of the printing material and the nozzle extrudate for additive manufacturing processes, such as Fused Filament Fabrication. The method includes implementing impregnation techniques for combining carbon nanotubes or other nano-fillers, a polymer resin and a fiber material to produce a polymer material that can be processed into a printing material. Further, the method may include combining the carbon nanotubes or other nano-fillers and the polymer resin to form a masterbatch that may be further combined with the fiber material through an extrusion process. The method results in a printing material with enhanced material properties and smooth surface finish for the printing material and resulting nozzle extrudate for Fused Filament Fabrication.

Abstract: A nozzle for dispense of a material that is a composite of fillers such as short fibers (e.g. carbon fibers) and a polymer matrix. The nozzle through which the composite material is dispensed has an expansion region through which the composite material flows. The expansion region dispenses a composite material wherein the fibers are substantially not aligned (e.g. in a random orientation with respect to each other in the polymer matrix).

Abstract: Methods for producing 3D printing composite polymer materials for use in additive manufacturing processes are provided. The methods result in enhancing the material properties of the printing material by providing a uniform and smooth surface finish of the printing material and the nozzle extrudate for additive manufacturing processes, such as Fused Filament Fabrication. The method includes implementing impregnation techniques for combining carbon nanotubes or other nano-fillers, a polymer resin and a fiber material to produce a polymer material that can be processed into a printing material. Further, the method may include combining the carbon nanotubes or other nano-fillers and the polymer resin to form a masterbatch that may be further combined with the fiber material through an extrusion process. The method results in a printing material with enhanced material properties and smooth surface finish for the printing material and resulting nozzle extrudate for Fused Filament Fabrication.

Abstract: Methods and systems are disclosed for structurally analyzing and/or three-dimensional printing a part. The method may comprise receiving a model of the part for three-dimensional printing from a material comprising a matrix, receiving one or more properties for the material, and using the model, determining a print head tool path for use during the three-dimensional printing of the part. The method may also comprise determining a trajectory of at least one stiffness-contributing portion of the material based at least in part on the print head tool path, determining a performance of the part based at least in part on the one or more properties and the trajectory, and electronically outputting the performance of the part.

Abstract: An article of manufacture is disclosed that is formed by jointly controlling a printhead and a worktable to provide three dimensional printing and insuring every point in a three dimensional print volume can be reached. Similarly, systems and methods are described to extend robot reach by coordinating robot and worktable control.

Abstract: The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.

Abstract: The present disclosure provides single-piece objects and methods for forming such objects. Such single-piece objects may be bicycle frames.

Abstract: The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.

Abstract: The present invention provides a system and method for the application of a functional thread to secure roving or other fibers to a substrate, thereby forming a precursor to a resultant composite component structure having targeted, enhanced structural reinforcement. The functional thread may be comprised of one or more fibrous filaments or have a monofilament structure. The invention encompasses the sewing of this functional thread at varying stitch densities as function of component stress analysis, the mechanical stresses that the component will be subject to when exposed to the forces and loads associated with its intended use, and at least one physical or mechanical property of a functional thread. This variable stitch density serves to provide targeted, localized mechanical enhancement and reinforcement to the resultant composite structure.

Abstract: The present invention provides a system and method for quickly removing and installing a filament tube and nozzle in an FFF extrusion system. The system utilizes a primary manifold that includes a cooling block, a heating block and a quick-change mechanism. This primary manifold is adapted to mate a filament tube/nozzle assembly. The quick-change mechanism, which in a particular embodiment utilizes a recessed biased-bearing arrangement, enables the filament/nozzle assembly to be removed and inserted without the use of any tools, and without causing any significant downtime for the FFF extrusion system. Once removed, the filament tube/nozzle assembly can be refurbished by a technician, trained so as not to over torque the tube/nozzle threaded interface. This refurbishment (typically consisting of a cleaning and the installation of a new nozzle) could be accomplished “off-line”, without any impact on the continued use of FFF extrusion system.

Abstract: The illustrative embodiment of the present invention uses a tangible three-dimensional structure as a fiducial mark, which structure is, at least partially, tolerant of dimensional variations in the article. The illustrative embodiment uses three such tangible three-dimensional structures: (1) a portion of a tangible conical surface, (2) a portion of a tangible spheroidal surface, and (3) a portion of a tangible pyramidal surface.

Abstract: A system and method for additive manufacturing of otherwise thermosetting polymers, such as PAI, is disclosed. The system includes fast-curing hardware that facilitates curing each deposited layer before a successive layer is deposited. This reduces the time to provide a finished part from weeks to hours.

Abstract: The present disclosure provides methods and systems for printing a three-dimensional (3D) object. A model of the 3D object, in computer memory, may be received. Next, at least one filament material from a source may be directed towards a build platform configured to support the 3D object, thereby depositing a first layer of a portion of the 3D object. The at least one filament material may be used to deposit a second layer corresponding to at least a portion of the 3D object. The first and second layers may be deposited in accordance with the model of the 3D object. While, the second layer is being deposited, at least one energy beam may selectively heat a first portion of the first layer and a second portion of the at least one filament material.

Abstract: A method and apparatus for additive manufacturing wherein a fiber composite filament having an arbitrarily shaped cross section is softened and then flattened to tape-like form factor for incorporation into a part that is being additively manufactured.

Abstract: A filament accumulator assembly is provided containing a filament inlet for receiving a continuous filament from the filament source and a filament outlet for receiving the continuous filament from the filament inlet, the continuous filament forming a filament loop between the filament exiting the filament inlet and entering the filament outlet. The filament accumulator assembly further comprises a filament track defining at least part of an inner boundary and an outer boundary of a circuitous filament route between the filament inlet and the filament outlet, and the filament loop is bound by the filament track. The filament loop has a diameter that varies across a range of potential diameters within the filament track.

Abstract: The illustrative embodiment of the present invention uses a tangible three-dimensional structure as a fiducial mark, which structure is, at least partially, tolerant of dimensional variations in the article. The illustrative embodiment uses three such tangible three-dimensional structures: (1) a portion of a tangible conical surface, (2) a portion of a tangible spheroidal surface, and (3) a portion of a tangible pyramidal surface.

Abstract: An article of manufacture is disclosed that comprises an infill made from linear segments of filament, such as but not limited to continuous carbon fiber-reinforced thermoplastic filament. Embodiments of the present invention comprises segments of filament in various geometries that distribute where adjacent segments overlap and are fused and where segments do not overlap. Embodiments of the present invention include quadrilateral (e.g., orthogonal, rectangular, etc.) infill and hexagonal (e.g., regular hexagonal, irregular hexagonal, convex hexagonal, etc.) infill.

Abstract: A consumable scaffold and technique for supporting an object while it is being manufactured is disclosed. The consumable scaffold comprises a base sheet and an array of pillars that are cantilevered from one side of the sheet. The consumable scaffold resembles a bed of nails. Each pillar in the array of pillars is trimmed to a desired length and the object is manufactured by fusing thermoplastic filaments to the tips of the pillars.

Abstract: The illustrative embodiment of the present invention uses a tangible three-dimensional structure as a fiducial mark, which structure is, at least partially, tolerant of dimensional variations in the article. The illustrative embodiment uses three such tangible three-dimensional structures: (1) a portion of a tangible conical surface, (2) a portion of a tangible spheroidal surface, and (3) a portion of a tangible pyramidal surface.

Abstract: The present invention provides a system and method for the application of a functional thread to secure roving or other fibers to a substrate, thereby forming a precursor to a resultant composite component structure having targeted, enhanced structural reinforcement. The functional thread may be comprised of one or more fibrous filaments or have a monofilament structure. The invention encompasses the sewing of this functional thread at varying stitch densities as function of component stress analysis, the mechanical stresses that the component will be subject to when exposed to the forces and loads associated with its intended use, and at least one physical or mechanical property of a functional thread. This variable stitch density serves to provide targeted, localized mechanical enhancement and reinforcement to the resultant composite structure.