Abstract: A pump system comprising a delivery assembly configured to feed a solid material under operational power of a first drive motor, and a screw pump comprising a housing that at least partially defines a barrel of the screw pump, an extrusion tip secured to the housing at a first end of the barrel, a liquefier secured to the housing and intersecting with the barrel, and an impeller extending at least partially through the barrel. The liquefier is configured to receive the solid material fed from the delivery assembly, to at least partially melt the received solid material, and to direct the at least partially melted material to the barrel, and the impeller is configured to drive the at least partially melted material that is directed to the barrel toward the extrusion tip under operational power of a second drive motor.

Abstract: A method and system for building one or more three-dimensional objects, where the method includes providing a computer-aided design model of a three-dimensional object having an initial spatial orientation in a coordinate system, and determining an optimal spatial orientation of the computer-aided design model in the coordinate system based on one or more criteria.

Abstract: A method for forming a surface-treated, three-dimensional object, comprising: solvent smoothing an exterior surface of a rapid-manufactured, three-dimensional object, and media blasting at least a portion of the solvent-smoothed exterior surface.

Abstract: A deposition modeling system incorporates a drive mechanism to feed a strand of filament to create a model. The drive mechanism comprises a pivot block that is rotatably connected to a fixed block and a motor that rotates a drive shaft. A drive roller is connected to the drive shaft and an idler roller is connected to an idler axle that extends from the pivot block in a substantially perpendicular direction to the direction of rotation of the pivot block with respect to the fixed block and in a substantially parallel direction to the drive shaft.

Abstract: The present invention is a method and apparatus for building three-dimensional models by deposition modeling techniques from moisture-sensitive thermoplastics. A feedstock of thermoplastic modeling material is dried to a low moisture content and supplied to a dispensing head of a modeling apparatus. The dry thermoplastic material is heated in a liquifier and deposited in a predetermined pattern so as to build a three-dimensional model.

Abstract: A three-dimensional model and its support structure are built by fused deposition modeling techniques, wherein a thermoplastic material containing silicone is used to form the support structure and/or the model. The thermoplastic material containing silicone exhibits good thermal stability, and resists build-up in the nozzle of an extrusion head or jetting head of a three-dimensional modeling apparatus. The silicone contained in a support material acts as a release agent to facilitate removal of the support structure from the model after its completion.

Abstract: A cassette for use in delivering a continuous length of filament. The cassette includes a housing having a first aperture and a spool rotatably mountable in the cassette housing. The spool contains a first female receptacle alignable with the first aperture, and a flexible boot is attached to the cassette housing and aligned with the first aperture. A removable plug is insertable through the first aperture and into the flexible boot for receipt within the first female receptacle of the spool to prevent rotation of the spool within the cassette housing.

Abstract: A method for building a three-dimensional object, the method includes positioning a metal part within a build chamber of an extrusion-based layered deposition system, where the metal part comprising a polymer-coated surface. The method also includes depositing a build material on the polymer-coated surface of the metal part, wherein the deposited build material cools to form at least a portion of a layer of the three-dimensional object.

Abstract: A three-dimensional model and its support structure are built by fused deposition modeling techniques, wherein a thermoplastic material containing silicone is used to form the support structure and/or the model. The thermoplastic material containing silicone exhibits good thermal stability, and resists build-up in the nozzle of an extrusion head or jetting head of a three-dimensional modeling apparatus. The silicone contained in a support material acts as a release agent to facilitate removal of the support structure from the model after its completion.

Abstract: A method for three-dimensional modeling builds up three-dimensional objects in a heated build chamber by dispensing modeling material from a dispensing head onto a base in a predetermined pattern. Physical and thermal separation are maintained between the heated build chamber and motion control components that control the motion of the dispensing head and the base. Thermal isolation of the motion control components from the build chamber allows the chamber to be maintained at a high temperature, and has other practical advantages as well.

Abstract: The present invention is a method for forming an object, the method comprising jetting a first material to form a plurality of layers that define a support structure increment, and extruding a second material to form a layer of the object. The layer of the object substantially conforms to an interior surface of the support structure increment.

Abstract: An extrusion head comprising at least one drive wheel and an assembly positionable between at least a first state and a second state. The assembly comprises a first extrusion line configured to engage the at least one drive wheel while the assembly is positioned in the first state, and a second extrusion line configured to engage the at least one drive wheel while the assembly is positioned in the second state.

Abstract: The present invention is a method for performing a calibration routine of a deposition device in a three-dimensional modeling machine that deposits a material to build up three-dimensional objects as directed by a controller on a substrate mounted on a platform. The method comprises generating a material build profile, which represents a three-dimensional structure at defined locations. A relative position of the material build profile is then determined. An expected build profile is identified and then compared to the determined relative position of the material build profile to identify any difference which represents an offset. The modeling system then positions the deposition device based upon the offset.

Abstract: A method and system for building one or more three-dimensional objects, where the method includes providing a computer-aided design model of a three-dimensional object having an initial spatial orientation in a coordinate system, and determining an optimal spatial orientation of the computer-aided design model in the coordinate system based on one or more criteria.

Abstract: Disclosed is a method for making a prototype plastic injection molded part from a mold tool (10) built by fused deposition modeling. The mold tool (10) is built by depositing roads of a molten thermoplastic resin in layers in a predetermined pattern defined by computer file data representing the inverse of the desired prototype molded part, and is used in an injection molding machine without the addition of any reinforcement fill material or layers to create the prototype part. The disclosed method provides prototype plastic injection molded parts within a twenty-four hour time period.

Abstract: A method of forming a three-dimensional object using an extrusion-based layered deposition system, the method comprising generating a build path for building a layer of the three-dimensional object, where the build path defines a void region. The method further comprising generating at least one intermediate path in the void region, and generating a remnant path based at least in part on the at least one intermediate path.

Abstract: The present invention is a method for forming an object, the method comprising jetting a first material to form a plurality of layers that define a support structure increment, and extruding a second material to form a layer of the object. The layer of the object substantially conforms to an interior surface of the support structure increment.

Abstract: A filament cassette and a filament loading assembly supply modeling filament to a liquifier in a three-dimensional deposition modeling machine. Two or more cassettes containing spooled filament are inserted into the machine. A strand of filament from a first one of the cassettes is fed to the liquifier for extrusion. Without operator intervention, the filament strand from the first cassette is withdrawn from the liquifier, and a filament strand from a second one of the cassettes is fed to the liquifier. The switching of filament feed sources is triggered by an event, such as an identification that the filament from the first cassette has reached a predetermined minimum length. In this manner, a used primary filament cassette is automatically replaced with a standby filament cassette, so that the machine need not experience downtime waiting for an operator to change the cassettes.

Abstract: Filament is loaded into an extrusion apparatus, such as a three-dimensional deposition modeling machine, by inserting a cassette containing filament into the apparatus. A filament strand from the cassette is then advanced into the machine, such as by operating a thumb wheel or a follower wheel on the cassette. The filament loading method of the present invention provides a convenient manner of loading and unloading filament in a three-dimensional modeling machine, and can be implemented in a manner that protects the filament from environmental moisture.

Abstract: A cassette for use in delivering a continuous length of filament. The cassette includes a housing having a first aperture and a spool rotatably mountable in the cassette housing. The spool contains a first female receptacle alignable with the first aperture, and a flexible boot is attached to the cassette housing and aligned with the first aperture. A removable plug is insertable through the first aperture and into the flexible boot for receipt within the first female receptacle of the spool to prevent rotation of the spool within the cassette housing.