Abstract: A three-dimensional printer for generating a printed component, includes a build substrate defining a surface that supports the printed component and a heated nozzle including a nozzle body. The heated nozzle is configured to deposit a build material upon either the build substrate or the printed component. The three-dimensional printer also includes a heated plate including one or more heating elements and a main body that defines an opening for receiving the nozzle body of the heated nozzle. The one or more heating elements are configured to heat at least a portion of the heated plate to a predefined temperature, where a volume of hot air is created between the heated plate and the printed component when the heated plate is heated to the predefined temperature.

Abstract: An X-arm carriage assembly for an additive manufacturing machine includes a magnet frame, a frame plate, a top plate and a bottom plate that define a rectangular shaped tube structure, first and second support brackets attached to first and second distal ends of the rectangular shaped tube structure to support the X-arm carriage assembly for movement along an x-axis, an encoder strip, a top linear rail mounted and a bottom linear rail adapted to moveably support a print head carriage on the X-arm carriage assembly along a y-axis, a longitudinal slot formed within the magnet frame, and a linear motor magnet track mounted onto the magnet frame in alignment with the longitudinal slot and extending longitudinally along the magnet frame, the linear motor magnet track including one of a single magnet and a plurality of magnets mounted adjacent one another.

Abstract: A control circuit for generating a primary alternating current (AC) voltage signal provided to a dielectric barrier discharge (DBD) disk of a three-dimensional printer includes a switching regulator receiving a direct current (DC) voltage signal. The switching regulator modulates the DC voltage signal based on a variable duty cycle to create a modulated DC signal. The control circuit also includes a modulation circuit in electrical communication with the switching regulator. The modulation circuit introduces a frequency component to the modulated DC signal, where the primary AC voltage signal includes a variable duty cycle and a set frequency, and the frequency component introduced into the modulated DC signal is representative of the set frequency of the primary AC voltage.

Abstract: Provided herein is a method for repairing a composite material, a layup manufacturing process of a composite and a system for manufacturing a 3-dimensional composite part. The method, process and system all utilize a dielectric barrier discharge applicator to generate a plasma to cure an epoxy material to bond a patch to a composite material or to bond two or more layers of composite material together in a 3-dimensional shape to form a composite part.

Abstract: A machine for manufacturing additive printed parts includes a first filament cartridge adapted to support a length of filament of a material from which the additive printed parts will be manufactured, a print head moveably supported within the machine, and a first filament buffer positioned between the first filament cartridge and the print head and including a first buffer volume. The filament supported within the first filament cartridge extends from the first filament cartridge, through the first filament buffer, and to the print head and is allowed to deflect within the first buffer volume.

Abstract: A prosthetic socket for a prosthetic limb is provided. The prosthetic socket comprises a socket body and a first and second structural members. The socket body comprises a distal end and a top edge opposite the distal end. The distal end comprises a prosthetic component attachment mechanism. The top edge comprises a medial fin, a lateral fin, a posterior edge and an anterior edge. The first and second structural members each include a first straight portion, a second straight portion, and a first arch portion. The first structural member is disposed on a medial exterior surface of the socket body and the second structural member is disposed on an lateral exterior surface of the socket body.

Abstract: A three-dimensional printer head includes a drive motor, the drive motor including a drive shaft, a feed plate is affixed to the drive motor, and a feed hob is mounted to the drive shaft. The feed hob includes drive teeth configured to engage a filament. An idle assembly mounted to the feed plate configured to bias the filament against the drive teeth. The printer head further includes a z-axis plate assembly, wherein the z-axis plate assembly includes at least two flexures coupling a z-axis plate to the feed plate and a print nozzle mounted to the z-axis plate assembly. The printer head also includes a sensor coupled to the feed plate, wherein the sensor is configured to be triggered by the z-axis plate assembly when the z-axis plate assembly moves a given distance in a first direction.

Abstract: A mold assembly for use in manufacturing parts includes a first and second mold halves and a mold temperature control system. The first mold half comprises at least a first mold cavity and a first coolant passage. The second mold half comprising at least a second mold cavity and a second coolant passage. The mold temperature control system is in fluid communication with the first and second coolant passages of the first and second mold half. The mold temperature control system comprises a fluid, a means to control the temperature of the fluid, and a pump to circulate the fluid through the mold temperature control system and the first and second coolant passages.

Abstract: A system and method for bonding a first layer of material to a second layer of material includes a first electrically conductive plate, a second electrically conductive plate spaced apart from the first electrically conductive plate. The second electrically conductive plate is electrically grounded. A high frequency generator in electrical communication with the first electrically conductive plate supplies high frequency electrical signals to the first electrically conductive plate. An adhesive applied to one of the first and second layers of material has an electromagnetic susceptor material that when subjected to the electric field heats the adhesive to an adhesive curing temperature to bond the first layer of material to the second layer of material. A clamping mechanism applies pressure to one of the first and second layers of material to maintain contact between the first and second layers until an adhesive cure time has lapsed.

Abstract: A three-dimensional printer for manufacturing additive printed parts includes a housing defining a cavity and first and second fixed rails extending along a first axis. First and second movable rails extend along a second axis and move independent of other another along the first axis. First and second print heads move along the second axis on the first and second movable rails, respectively, and first, second, and third dividers collectively separate the cavity to partially define process and instrument chambers. The first divider is mounted to the housing and the first movable rail and expands and contracts with the movement of the first movable rail. The second divider is mounted to the housing and the second movable rail and expands and contracts with the movement of the second movable rail. The third divider is mounted to the movable rails and expands and contracts with the movement of the movable rails.

Abstract: A three-dimensional printer and a method of leveling a support surface in a three-dimensional printer. The three-dimensional printer includes a base plate, a support bed, including a support surface, wherein the support bed is mounted to the base plate, a plurality of adjustable mounting assemblies adjustably mounting the base plate to the support bed, wherein each adjustable mount assembly separates the base plate from the support bed by a first distance. The three-dimensional printer may further include a vacuum port fluid communication with a vacuum opening, a vacuum pump in fluid communication with the vacuum port, a vacuum regulator coupled to the tubing between the vacuum pump and vacuum port, and a vacuum pressure switch coupled to the tubing between the vacuum regulator and the vacuum port.

Abstract: A thermoplastic composite material includes a thermoplastic polymer matrix component, a microparticle component, a nanoparticle component, and a compatibilizing agent component, at least a portion of the microparticle component and/or nanoparticle component is a natural fiber.