Abstract: The present invention relates to a method for functionalizing a workpiece surface, comprising the following steps: a) providing a workpiece; b) providing a film; c) functionalizing at least one film side by the location-selective application of a functionalization composition comprising a polymer material onto part of the film side in one or more layers by means of a 3D printing process; d) creating an integrally bonded or interlocking connection between the workpiece surface and the film functionalized in step c) by bringing the film into contact with at least part of the workpiece surface, wherein the integrally bonded or interlocking connection to the workpiece surface is achieved with a functionalized film side. The invention further relates to workpieces having a surface functionalized according to the invention.

Abstract: A method for generating print images for additive manufacturing includes: accessing a part model; accessing a set of dimensional tolerances for the part model; and segmenting the part model into a set of model layers. The method also includes, and, for each model layer: detecting an edge in the model layer; assigning a dimensional tolerance to the edge; defining an outer exposure shell inset from the edge by an erosion distance inversely proportional to a width of the dimensional tolerance; defining an inner exposure shell inset from the outer exposure shell and scheduled for exposure separately from the outer exposure shell; defining an a outer exposure energy proportional to the width of the dimensional tolerance and assigned to the outer exposure shell; and defining an inner exposure energy greater than the outer exposure energy and assigned to the inner exposure shell.

Abstract: Thermoset compositions and methods for forming three-dimensional articles via an additive fabrication process, and articles made therefrom are disclosed herein. In an embodiment, a composition comprises a first network-forming component comprising a TPA-based polyester comprising a backbone and having at least 2 polymerizable groups, one or more first network monomers, and a first network initiator. The backbone of the TPA-based polyester comprises the reaction product of a terephthalic acid and a polyol. The composition may further comprise a second network-forming component.

Abstract: An induction sensing method for identifying the center of a tip surface of a nozzle of print head of a 3D printer includes providing an eddy current sensor in a fixed position and providing a metal nozzle with a tip orifice in a main body and a tip surface about the tip orifice. The method includes moving the metal nozzle over the eddy current sensor in a predetermined motion path above the eddy current sensor while the eddy current sensor remains stationary and samples the magnitude of inductance in a generated inductive field, thereby generating a curve representing the inductive field. The method includes identifying a maximum amplitude of the curve to identify the center of the tip surface.

Abstract: The invention relates to a method for producing an at least partially coated object, comprising the step of producing the object from a construction material by means of an additive manufacturing method, the construction material comprising a thermoplastic polyurethane material. Following the production of the object, the method comprises the step of at least partially bringing a preparation into contact with the object, the preparation being selected from: an aqueous polyurethane dispersion; an aqueous dispersion of a polymer comprising OH groups, this dispersion also containing a compound comprising NCO groups; an aqueous preparation of a compound containing NCO groups, but not containing any polymers comprising OH groups; or a combination of at least two thereof. The invention also relates to an at least partially coated object that was obtained by a method according to the invention.

Abstract: Disclosed herein are expanding spinal fusion cage embodiments including an expandable cage assembly configured to expand from a collapsed state to an expanded state in an intervertebral space when inflated with a material. The assembly can include an inflatable section defining an interior volume configured to receive the material and expand the interior volume in response to a pressure from the received material to cause the expandable cage assembly to transition from the collapsed state to the expanded state, and a stabilization section configured to restrain the inflatable section during inflation.

Abstract: A sulfonated water-dispersible thermoplastic copolymer material for use as a support material in an additive manufacturing process is made by a method comprising providing a selected thermoplastic copolymer having an acid or an anhydride group; esterifying the acid group of the selected thermoplastic copolymer with a hydroxyl-functionalized sulfonate salt, or amidizing the acid group of the selected thermoplastic copolymer with an amine sulfonate salt, or imidizing the anhydride group of the selected thermoplastic copolymer with an amine sulfonate salt. The esterification, the amidization or the imidization results in a sulfonated water thermoplastic dispersible copolymer having a glass transition temperature suitable to provide an effective support during the additive manufacturing process and wherein the sulfonated water-dispersible thermoplastic copolymer will disperse in tap water in less than 1 hour.

Abstract: A method for calibrating a 3D printer includes the steps of providing information obtained in a factory calibration indicating a center of an inner diameter of a tip orifice in a metal extrusion nozzle and a center of a tip surface for the nozzle and inductively sensing the nozzle with an eddy current sensor when secured to a print head on a gantry or robotic arm of the 3D printer to identify a sensed location of the center of the tip surface of the nozzle. The method includes determining a location of the center of the inner diameter of the tip orifice on the nozzle on the print head and utilizing the provided information to locate the center of the inner diameter of the tip orifice.

Abstract: A method of printing a 3D part with an additive manufacturing system includes printing a first portion of the part and pre-heating the first portion of the part along an upcoming tool path to a temperature at or above a material-specific bonding temperature and below a degradation temperature of the material. Material is extruding material onto the first portion along the pre-heated tool path while the temperature along the part surface remains at or above a material-specific bonding temperature and below the degradation temperature of the material thereby forming a newly extruded road. The method includes cooling the newly extruded road along the pre-heated tool path to remove heat imparted by the preheating step such that a thermally stable temperature is reached, wherein the preheating, extruding and cooling is performed in less than ten seconds.

Abstract: A polymeric material used for 3D printing is preheated, at a first zone in a 3D printer, to a temperature in excess of its glass transition temperature prior to being melted, at a second zone, for incorporation into a build object. This enables the polymer to be processed more rapidly than in the prior art.

Abstract: It is a feature of a porous body (10, 20) comprising a three-dimensional network of node points (200) joined to one another by struts (100), and a void volume (300) present between the struts (100), that the struts (100) have an average length of ?200 to ?50 mm, the struts (100) have an average thickness of ?100 ?m to ?5 mm, and that the porous body has a compression hardness (40% compression, DIN EN ISO 3386-1: 2010-09) in at least one spatial direction of ?10 to ?100 kPa. The porous body according to the invention combines the advantages of a conventional mattress or cushion with ventilatability which results from its porous structure and is not achievable in conventional foams. The invention further relates to a method of producing such a porous body (10, 20) and to an apparatus comprising said body (10, 20) for supporting and/or bearing a person.

Abstract: A platen assembly for use with an extrusion-based 3D printer includes a grid assembly comprising at least a 4×2 framework of interlocked perpendicular x direction beams and y direction beams, providing a substantially planar upper surface and a bottom surface. The platen assembly includes a platen comprising a thin metal sheet supported on the upper surface of the grid assembly and secured to the grid assembly such that the top surface provides a substantially flat build surface. The x direction beams, the y direction beams and the platen are constructed of substantially a same thermal expansion properties, and wherein the build surface of the platen has a build surface area of at least 400 square inches and maintains its flatness to within a flatness tolerance of 0.020 inches over a temperature range of at least 20 C-300 C.

Abstract: The present disclosure is directed to pulverulent thermoplastic polymer blends comminuted to a particle size of less than 300 ?m. The pulverulent thermoplastic polymer blends can include a first thermoplastic polyurethane and a second thermoplastic polyurethane at a weight ratio of from about 90:10 to about 30:70 first thermoplastic polyurethane to second thermoplastic polyurethane. The first thermoplastic polyurethane can include a reaction product of a first reaction mixture consisting of or consisting essentially of an aliphatic diisocyanate having a number average molecular weight of from 140 g/mol to 170 g/mol and an aliphatic diol having a number average molecular weight of from 62 g/mol to 120 g/mol.

Abstract: The hardware and software properties of a three-dimensional printer can be queried and applied to select suitable directly printable models for the printer, or to identify situations where a new machine-ready model must be generated. The properties may be any properties relevant to fabrication including, e.g., physical properties of the printer, printer firmware, user settings, hardware configurations, and so forth. A printer may respond to configuration queries with a dictionary of capabilities or properties, and this dictionary may be used to select suitable models, or determine when a new model must be created. Similarly, when a printable model is sent to the printer, metadata for the printable model may be compared to printer properties in the dictionary to ensure that the model can be fabricated by the printer.

Abstract: An additive manufacturing system including a base assembly and a tray assembly. The base assembly includes a build window, substantially transparent to electromagnetic radiation; a projection system configured to project electromagnetic radiation toward an upper surface of the build window; and a tray seat arranged around a perimeter of the build window. The tray assembly is configured to engage with the base assembly in an engaged configuration and includes: a tray structure defining a registration feature configured to engage the tray seat to locate an aperture proximal to the upper surface of the build window in the engaged configuration; and a separation membrane that is configured to laminate across the upper surface of the build window in response to an evacuation of gas from an interstitial region and configured to separate from the build window in response to injection of gas into the interstitial region.

Abstract: A filament for use in an extrusion-based additive manufacturing system includes an elastomeric core and a harder, non-elastomeric shell. The core compositionally comprising an elastomeric core material having a flexural modulus of less than 31,000 psi and a durometer of less than 80 Shore. The shell overlays the core portion and compositionally comprises a non-elastomeric thermoplastic shell material that is substantially miscible with the elastomeric core material, wherein the core material and the shell material have the same monomer chemistry. The non-elastomeric thermoplastic shell material has a flexural modulus that is greater than the flexural modulus of the elastomeric core material by at least a factor of five, wherein the shell provides sufficient strength or stiffness to the filament such that filament can be utilized as a feedstock in the extrusion-based additive manufacturing system.

Abstract: A method includes: accessing a part model comprising a three-dimensional representation of a part; accessing a material profile relating exposure energy and three-dimensional polymerization geometry of a material selected for the part; segmenting the part model into a set of model layers; detecting a first upward-facing surface in the part model; defining a first model volume in a first model layer, adjacent the first upward-facing surface, and fully contained within the part model; based on the material profile, calculating a first exposure energy predicted to yield a first three-dimensional polymerization geometry approximating a first contour of the first upward-facing surface when projected onto the material during a build; populating a first print image with the first exposure energy in a first image area corresponding to the first model volume in the first model layer; and storing the first print image in a print file for the part.

Abstract: A build chamber for a 3D printer includes a heated build space in an interior of the build chamber and a thermal isolator configured to insulate 3D printer components from the heated build space. The thermal isolator includes a first baffle section and a second baffle section. Each of the first baffle section and the second baffle section includes an accordion-pleated panel having a length, a width, a first end and a second end, wherein the panel comprises a parallel alternating top folds and bottom folds along the width forming a series of pleats, and each pleat within the series being configured to expand and contract, and wherein the panel is constructed of a heat-resistant material. Each baffle section also includes support rods affixed to the accordion-pleated panel in parallel to the pleats and at intervals along the length of the panel, the support rods substantially spanning the width of the panel.