Abstract: Ducts manufactured by depositing one or more runs of material in a helix, a plurality of conjoined planar spirals, and a conjoined plurality of conical spirals.

Abstract: A filament guide that guides thermoplastic filament to an object being manufactured. A deposition head comprising the disclosed filament guide provides a filament to the intended deposition point. The filament guide comprises a guide member having a filament groove configured to guide the filament along a path of travel. The groove has an upstream end that is configured to receive the filament from a source and a downstream end that is configured to direct the filament toward the deposition point in the intended direction. A notch at the downstream end of the guide member enables the filament to travel toward the deposition point. The portions of the guide member on either side of the notch act to keep the filament centered laterally. A plate that is transparent to electromagnetic radiation from a heat source covers the groove and permits the electromagnetic radiation to reach the filament while providing added support.

Abstract: Ducts manufactured by depositing one or more runs of material in a helix, a plurality of conjoined planar spirals, and a conjoined plurality of conical spirals.

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: A process of additive manufacturing in which a stack of non-planar layers of material are deposited for manufacturing an object. The non-planar layers can conform to the surface of the object or not. The non-planar layers can create structurally-advantageous interior structures in the object. The contours of the non-planar layers can be different or can be the same.

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: An apparatus and method for managing bending and other applied forces that are exerted on a filament of thermoplastic with reinforcing fibers in a 3D printing system during the deposition process that is associated with the manufacturing of an object. The quality of the manufactured object is enhanced through a process that comprises i) applying torque to certain portions of the solid filament in a manner that is commensurate with the expected motions of the deposition head while depositing those portions, but only after ii) heating each portion to a sufficient temperature. A heating device and a twisting device act on the filament while it is moving toward the deposition point and while under the control of a controller that is operating according to a computer model of the object being manufactured.

Abstract: Curvilinear ducts manufactured by depositing one or more runs of material in a conjoined helix, a conjoined plurality of conjoined planar spirals, and a plurality of conjoined conical spirals.

Abstract: A method for forming a blended material for use as a deposition material in a fused filament fabrication (FFF) printer is provided. A semi-crystalline material and an amorphous material are physically mixed at an appropriate ratio. The mixed material is then heated to a temperature that is above the melting point of the semi-crystalline material and above the glass transition temperature of the amorphous material to form a blended material. The blended material is then extruded through an extruder die for use in the FFF printer.

Abstract: An apparatus for manufacturing an object includes an extrusion head having an extrusion needle for extruding thermoplastic material associated with one or more fiber strands. The apparatus may further include a turn-table, a more robotic arm for moving the extrusion head and needle, thermoplastic filament and fiber strand spools and thermoplastic filament and fiber strands. A controller is provided for directing the robotic arm, extrusion head and the turn-table. Further, a method for manufacturing an object includes generating a design for the object that substantially satisfies desired structural properties of the object and generating a sequence for extruding one or more beads of thermoplastic material to manufacture the object according to the design, in which the one or more beads of thermoplastic material are associated with one or more fiber strands. The one or more beads of thermoplastic material and the associated one or more fiber strands are then extruded according to the sequence.

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: The present invention relates to a system and a method for optimizing printing parameters, such as slicing parameters and tool path instructions, for additive manufacturing. The present invention comprises a property analysis module that predicts and analyses properties of a filament object model, representing a constructed 3D object. The filament object model is generated based on the tool path instructions and user specified object properties. Analysis includes comparing the predicted filament object model properties with the user specified property requirements; and further modifying the printing parameters in order to meet the user specified property requirements.

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: 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 apparatus performing as a base for printing 3D objects using high temperature thermoplastics employing additive manufacturing methods is provided. The apparatus comprises a heated build platform, a thin removable plate secured on top of the build platform, a high temperature polymer coating applied over the removable plate, and surface treatment of high temperature polymer coating to maintain adhesion between 3D object and printing surface. Also, the removable plate has low coefficient of thermal expansion compared to build platform below it, for avoiding bowing of the plate as it is heated due to heated build platform, hence providing flat printing surface. The thin removable plate allows 3D objects to pop off the plate upon cooling, without damaging the polymer coating, the plate, or the object. It also allows for continuous operation of printing, while the plate is released for cooling, a new plate is installed for printing.