Abstract: A method for generating a more accurate mesh that represents a 3D printed part based on a model includes slicing the model into layers and identifying an infill-wall boundary and an exterior-interior boundary of each layer of the model. Layers of the model may be identified as critical by iterative comparison with adjacent layers. An interior voxel mesh may be constructed based on common two-dimensional reference grids imposed on the critical layers. The interior voxel mesh may be augmented to an augmented mesh and then extended to a protomesh. The protomesh may be extruded to construct the final mesh, which may be analyzed by finite element analysis. The part may be 3D printed based on the layers output by the slicing operation.

Abstract: According to one aspect, embodiments herein provide a furnace for debinding and sintering additively manufactured parts comprising a unitarily formed retort having at least one open side, a heater for heating a sintering volume within the retort to a debinding temperature and to a sintering temperature, an end cap sealing the at least one open side, a forming gas line penetrating the end cap for supplying forming gas at a flowrate, and a heat exchanger within the retort, outside the sintering volume, and adjacent a heated wall of the retort, the heat exchanger having an inlet connected to the forming gas line and an outlet to the sintering volume, wherein the heat exchanger includes a heat exchange tube length sufficient to heat the forming gas to within 20 degrees Celsius of the sintering temperature before the forming gas exits the outlet.

Abstract: A flexible 3D printing feedstock material is disclosed. The flexible 3D printing feedstock material includes 45-80 vol % of a powder having at least one of a metal powder and a ceramic powder, 0-5 vol % of a compatibilizer, 10-35 vol % of a soluble flexibilizer, and 5-35 vol % of a non-soluble binder component. Methods of forming the flexible 3D printing feedstock material by melt mixing the components are disclosed. Methods of producing a 3D printed part by operating a fused deposition modeling 3D printer loaded with a filament formed of the 3D printing feedstock material are also disclosed.

Abstract: A three-dimensional geometry is received, and sliced into layers. A first anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material is generated defining at least part of an interior of a first layer. A second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material defines at least part of an interior of a second layer. A generated isotropic fill material tool path defines at least part of a perimeter and at least part of an interior of a third layer intervening between the first and second layers.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.

Abstract: A material for producing a three-dimensionally printed part including a metal material and at least one sintering aid in an amount effective to give the three-dimensionally printed part a density of between about 90% and about 100% after sintering is disclosed. A method of printing a three-dimensional part including selecting a metal material, incorporating at least one sintering aid into the metal material to form a print material, and printing the three-dimensional part is also disclosed. A method of producing a sintered metal part including providing a metal material for the sintered metal part incorporating boron as a first sintering aid, incorporating phosphorus as a second sintering aid, forming the metal part in a predetermined form the metal material, and heating the formed metal part to a sintering temperature is also disclosed. Three-dimensionally printed parts are also disclosed.

Abstract: Systems, apparatus and methods of additively manufacturing objects are disclosed. Specifically, provided herein are methods of heating objects having a particle-based support at least partially surrounding the object during portions of stages of the heating. Additionally, systems, apparatus, and methods for removing the particle-based support during heating, such that the object can continue heating to form a final part. Systems, apparatus, and methods for distributing the particle-based support to shore the objects through heating are disclosed. Systems, apparatus, and methods for removing the particle-based support are also disclosed herein.

Abstract: In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.

Abstract: Techniques for manufacturing optimization using a multi-tenant machine learning platform are disclosed. A method for manufacturing optimization includes: obtaining physical sensor data, by a manufacturing device associated with a tenant of a multi-tenant machine learning platform; determining, by a machine learning spoke system associated with the tenant, a machine learning parameter based on at least the physical sensor data; preventing exposure of the first physical sensor data of the first manufacturing device to any other tenant of the multi-tenant machine learning platform; transmitting the machine learning parameter from the machine learning spoke system to a machine learning hub system of the multi-tenant machine learning platform; and updating, by the machine learning hub system, a multi-tenant machine learning model based at least on the machine learning parameter.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.

Abstract: Methods for additive manufacturing using a three-dimensional printer including at least one linear feed mechanism and a print head positioned proximate a build platen are disclosed. The methods include a step of providing and/or feeding an unmelted fiber reinforced composite filament at a feed rate by the at least one linear feed mechanism. The methods include heating the filament to a temperature at which a matrix material therein flows within at least one rounded outlet of the print head. The methods include moving the print head and the build platen relative to one another at a printing rate. The methods include applying a spreading force to the filament between the at least one rounded outlet of the print head and the build platen. The methods include a step of controlling a differential in the feed rate and printing rate using the at least one linear feed mechanism so that the feed rate and the printing rate are substantially the same.

Abstract: A method of 3D printing an object includes receiving design information corresponding to an object for which a printed object is to be generated by a 3D printing operation according to a first set of print instructions, generating a plurality of measurement locations, printing successive layers which form the object, measuring the object at the measurement locations to form measurement data, comparing the measurement data with expected measurements of the measurement locations based on the design information, and generating, based on the comparing, deviation information. The measurement locations represent locations of the object to be measured by a measurement device. The deviation information represents deviations between the printed object following completion of the printing, and the object represented by the design information.

Abstract: In a method for additive manufacturing, a multi-strand core reinforced filament including a flowable matrix material and substantially continuous reinforcing strands extending in a direction parallel to a length of the filament is supplied. A first consolidated composite swath of a height less than ½ the width of the filament is deposited in a first reinforcement formation including at least one straight path and at least one curved path against a deposition surface, and a second consolidated composite swath of a height less than ½ the width of the filament is deposited in a second reinforcement formation against the first consolidated composite swath. Each deposition flows the matrix material and applies an ironing force to spread the reinforcing strands within the filament against the underlying surface and/or previously deposited swath.

Abstract: According to one aspect, embodiments herein provide a method of reducing distortion in an additively manufactured part comprising forming a shrinking platform from a composite including metal particles embedded in a first matrix, forming shrinking supports from the composite, forming a part from the composite upon the shrinking platform and shrinking supports, forming an interior structure in at least one of the shrinking platform, the shrinking supports, and the part having a plurality of chambers with interconnections therebetween, forming from the shrinking platform, the sintering supports, and the part a portable assembly, and debinding the first matrix in the portable assembly to form a portable assembly in a brown state, wherein debinding the first matrix includes penetrating a fluid debinder into the interior structure of the at least one of the shrinking platform, the shrinking supports, and the part to debind the first matrix from within the interior structure.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to applying the filament from the conduit nozzle.

Abstract: According to one aspect, embodiments herein provide a method for in-process inspection of a 3D printed part with a 3D printer, comprising slicing a three dimensional model to define a plurality of shell volumes, for substantially each shell volume, generating a toolpath for depositing a printing material shell corresponding to the shell volume, transmitting, together with an identification, the toolpaths defining the printing material shells for deposition by a 3D printer, receiving, together with the identification, from the 3D printer a scanned surface profile of a printing material shell, and computing a process inspection including, according to the identification, a comparison between a received scanned surface profile and a toolpath defining a printing material shell.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.

Abstract: In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.

Abstract: In additive manufacturing, a composite build material filament and a release material filament are dropped from respective spools to a print head. Each of the composite build material filament and the release material filament includes a metal or ceramic powder plus a binder. On the spools and over the drop height, the filaments are heated to a temperature that flexes the filaments but does not soften them to a breaking point. The drop height is of similar linear scale to the build plate. The materials are debound and sintered.