Abstract: A support material feedstock comprising a first copolymer and a polymeric impact modifier, where the first copolymer includes a first monomer unit comprising a carboxyl group and a second monomer unit comprising a phenyl group.

Abstract: A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a topographical surface pattern that is configured to engage with a drive mechanism of the extrusion-based digital manufacturing system.

Abstract: The present invention is a composition for making a three-dimensional object. The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solution.

Abstract: Three-dimensional parts having porous protective structures built with powder-based additive manufacturing systems, the porous protective structures being configured to protect the three-dimensional parts from damage during de-powdering processes.

Abstract: A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.

Abstract: A detector for use in an extrusion-based digital manufacturing system, the detector comprising a sense conductive component and an excitation conductive component to define a first gap that is configured to receive a consumable material used in the extrusion-based digital manufacturing system, where the excitation conductive component is configured to generate a first electrical field across the first gap.

Abstract: A method for building a three-dimensional object in a layer-by-layer manner, the method comprising heating a build chamber of a digital manufacturing system, feeding a solid feedstock of a modeling material comprising an amorphous metallic alloy to a liquefier assembly of the digital manufacturing system, heating the modeling material of the solid feedstock in the liquefier assembly to an extrudable state, and depositing the heated modeling material within the heated build chamber in a predetermined pattern to form the three-dimensional object.

Abstract: A container comprising a housing that is configured to rotatably mount a filament supply spool, and a filament guide mechanism mountable within a channel of the housing, where the filament guide mechanism comprises a filament pathway configured to guide the filament from the filament supply spool rotatably mounted in the interior chamber, and a sensor configured to detect the presence of the filament through at least a portion of the filament pathway.

Abstract: A head mount for use in a digital manufacturing system, where the head mount comprises a first component supported by at least one gantry of the digital manufacturing system, and a second component configured to retain a deposition head of the digital manufacturing system, and to move relative to the first component in response to a load applied to the deposition head from a platform assembly of the digital manufacturing system.

Abstract: A platform assembly for use in a digital manufacturing system, where the platform assembly comprises a deformable platform having a surface configured to operably receive a deposited material from a deposition head, and at least one mechanism configured to adjust at least a portion of the first surface to compensate for at least one vertical deviation from at least one horizontal axis that the deposition head is directed to move in.

Abstract: A method comprising building at least one three-dimensional model and a support structure using a layer-based additive technique, where the at least one three-dimensional model is at least partially encased in the support structure, and where the support structure functions as a shipping package for the at least one three-dimensional model.

Abstract: A filament spool for use in a filament spool container, where the filament spool comprises a first rim and a second rim offset by an axial shaft, and a series of grooves extending along a first portion of the first rim and configured to receive a filament of a material while the filament is wound around the axial shaft in a first rotational direction.

Abstract: Disclosed is a method for smoothing the surface of an object built from a polymeric or wax material using a layered manufacturing rapid prototyping technique. After the object is built it is exposed to a vaporized solvent such as in a vaporizer for an exposure time sufficient to reflow the object surface. A solvent is chosen based on its ability to transiently soften the material which forms the object, and thereafter evaporate off the object. The object is removed from the solvent and allowed to dry, producing a smooth finished part.

Abstract: A system and method is provided for vapor smoothing a rapid manufactured three-dimensional object. A cabinet housing has a sealable interior. A heated vapor chamber in the interior of the cabinet housing contains solvent that is vaporizable to fill the vapor chamber with vapor for smoothing the object when the object is placed in the vapor chamber. A drying chamber is also provided in the interior of the cabinet housing that is separate from the vapor chamber for drying the object when the object is moved from the vapor chamber to the drying chamber.

Abstract: A system for building a three-dimensional object with a layer-based additive technique, the system comprising a controller configured to receive build sequence data for the three-dimensional object, a head assembly in signal communication with the controller and configured to form a plurality of layers of the three-dimensional object based on the build sequence data, and an insert placement apparatus in signal communication with the controller and configured to place at least one insert in the plurality of formed layers based on the build sequence data.

Abstract: A method for modifying a computer-aided design model of a three-dimensional object, the method comprising establishing a threshold wall width, providing at least one sliced layer polyline of the computer-aided design model, determining a first distance between first and second portions of the at least one sliced layer polyline, and adjusting locations of the first and second portion to provide a second distance if the first distance is less than the threshold wall width, where the second distance is about equal to the threshold wall width, or greater.

Abstract: A digital manufacturing system for producing first and second objects comprises a platen, a gantry, a pantograph extrusion head system and first and second sets of extruders. The platen defines a workspace upon which the objects are produced. The gantry defines a headspace displaced from the workspace. The extrusion head system is mounted to the gantry for movement in the headspace. The sets of extruders are connected to the extrusion head system and are configured to deposit extrusion material on the workspace to build the objects. Each set of extruders comprises a first extruder mounted to the extrusion head system; a second extruder mounted to the extrusion head system so as to be actuatable from a first to a second position; and a flexible linkage connecting the extruders. The flexible linkages position the second extruders in approximately equal known spatial relationships to the first extruders in the second positions.