Abstract: An additive manufacturing system and process for producing three-dimensional parts, which includes forming layers of the three-dimensional part from a part material at a first resolution, and ablating selected voxels of the formed layers with a laser beam at a second resolution that is higher than the first resolution.

Abstract: A method includes receiving an indication that a 3D printer has encountered an error printing an instance of a 3D print job and selecting an idle 3D printer to print the instance of the 3D print job. Previous printing instructions for the instance of the 3D print job are changed based on the selected idle 3D printer and the changed printing instructions are provided to the selected idle 3D printer.

Abstract: A support material for use in an additive manufacturing system, which includes a thermoplastic copolymer polymerized from monomers comprising acid-functional monomers having carboxylic acid groups, and one or more non-acid-functional monomers, where a portion of the carboxylic acid groups are neutralized with a base having an alkali metal cation. The thermoplastic copolymer has a high glass transition temperature and melt processing temperature, and is thermally stable at its melt processing temperature. The neutralized thermoplastic copolymer is soluble in an alkaline aqueous solution.

Abstract: A three-dimensional model built with an extrusion-based digital manufacturing system, and having a perimeter based on a contour tool path that defines an interior region of a layer of the three-dimensional model, where at least one of a start point and a stop point of the contour tool path is located within the interior region of the layer.

Abstract: A pump assembly for use in an additive manufacturing system includes a viscosity pump having a first end and a second end wherein the first end has a cross sectional area greater than a cross sectional area of the second end. The viscosity pump has a conical shaped inner surface defining a pump chamber, an inlet proximate the first end and an outlet proximate the second end. The viscosity pump includes an impeller having an axis of rotation, where the impeller has a shaft positioned through the first end of the first housing and into the pump chamber. The impeller includes a distal tip-end at a distal end of the shaft wherein the impeller is configured to be axially displaced within the pump chamber of the viscosity pump parallel to the axis of rotation. An actuator is coupled to a proximal end of the impeller, wherein the actuator is configured to move the impeller parallel to the axis of rotation.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system, the method comprising generating and printing a planarizing part having a substantially-planar top surface relative to a build plane, and a bottom surface that substantially mirrors a topography of a platen surface, and printing the three-dimensional part over the substantially-planar top surface of the printed planarizing part.

Abstract: A starter piece for printing a three-dimensional item includes a main body having a face surface, a keel coupled to the main body, a guide tab extending from the keel, and at least one retaining mechanism coupled to the main body. Printing a three-dimensional item with an additive manufacturing system having a print foundation, a print head configured to print the three-dimensional item, and a plurality of support rails includes printing a support structure for the three-dimensional item in a layer by layer manner along the printing axis along with the printing of the three-dimensional item. The support structure is printed to provide a support between the three-dimensional item and the plurality of support rails of the additive manufacturing system.

Abstract: A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly.

Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a matrix of a first base polymer and particles dispersed within the matrix, and a shell portion comprising a same or a different base polymer. The consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional part, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament and retain the particles within the roads of the printed part and do not penetrate the outer surface of the shell portion.

Abstract: Method for printing a three-dimensional part layerwise with an additive manufacturing system includes printing layers by depositing material from a print head onto a print foundation, incrementing a position of the print head relative to the print foundation after each layer is printed, and indexing the print foundation carrying the printed layers away from the print head along the printing axis after a number of layers are printed. Printing is performed with driven and fixed rails clamped against movement of the print foundation. Moving the print foundation includes moving the driven rails with respect to the fixed rails in a direction substantially perpendicular to the build plane. Additive manufacturing system includes a drive mechanism to index the print foundation on the printing axis using fixed and driven rails, the driven rails engaging the print foundation for moving the print foundation.

Abstract: An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.

Abstract: An additive manufacturing device includes at least one liquefier assembly that receives filament material from at least one feedstock and extrudes the material in a flowable form. A thermal drying system removes water vapor and heats compressed air to a preselected temperature set point to form conditioned air. At least one enclosed filament path houses and guides the filament material from a supply to the at least one liquefier assembly. The enclosed filament path is exposed to the conditioned air from the thermal drying system so as to keep the filament material dry as it is fed to the at least one liquefier assembly.

Abstract: A platen assembly for use in a 3D printer includes a frame and a platen supported by the frame. The platen is configured to receive a removable build tray. A lever release mechanism of the platen assembly is coupled to the frame and is configured to both secure the build tray to the platen for printing of the part, and to eject the build tray from the platen after printing of the part.

Abstract: An assembly for use in an additive manufacturing system to print a three-dimensional part that includes an extruder comprising a gear and a motor that turns the gear, wherein rotation of the gear regulates a flow of material out of the extruder. A controller, provides a control signal to the motor to control the rate at which the motor turns the at least one gear and incorporates a time-varying signal into the control signal to reduce ripples in the material output by the extruder.

Abstract: An 3D printer has a gantry configured to move in a plane substantially parallel to a build plane. The system includes a platen configured to support a part being built in a layer by layer process, wherein the platen is configured to move in a direction substantially normal to the build plane. The system includes a head carriage carried by the gantry wherein the head carriage includes a first support member supporting a retaining mechanism. The retaining mechanism includes at least one member extending from the support member and a camming member rotatably attached to the support member and movable about an axis of rotation. The camming member has arcuate camming surface with an increasing radial distance from the axis of rotation. The system includes at least one print head having a housing with a first side surface configured to engage the at least one member and a second side surface configured to engage the arcuate camming surface.

Abstract: A ribbon liquefier comprising an outer liquefier portion configured to receive thermal energy from a heat transfer component, and a channel at least partially defined by the outer liquefier portion, where the channel has dimensions that are configured to receive the ribbon filament, and where the ribbon liquefier is configured to melt the ribbon filament received in the channel to at least an extrudable state with the received thermal energy to provide a melt flow. The dimensions of the channel are further configured to conform the melt flow from an axially-asymmetric flow to a substantially axially-symmetric flow in an extrusion tip connected to the ribbon liquefier.

Abstract: A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.

Abstract: A 3D printer includes at least one consumable loading bay configured to supply filament from a consumable supply assembly to a print head and at least one drive assembly that is configured to advance filament to the print head from the consumable supply. Each drive assembly includes a follower wheel rotatable about a follower axis and a drive wheel spaced apart from the follower wheel. The drive wheel is rotatable about a drive axis and is located on an opposing side of a filament path from the follower wheel such that the follower axis and the drive axis are substantially parallel. The drive wheel further includes an outer surface extending between two ends and has at least one engaging portion that is configured to engage with the filament and at least one disengaging portion that is configured to disengage from the filament.

Abstract: A method to form a part in an additive manufacturing system includes providing a melt pool configured to retain and dispense an electrically resistive consumable material and an array of channels in fluid communication with the melt pool. The method includes providing an array of channels in fluid communication with the melt pool, where each of the array of channels have a hollow electrically conductive nozzles wherein each of the array of nozzles is coupled to a distal end of one of the array of channels such that the consumable material can flow from the melt pool to each of the nozzles. The method includes providing a grid spaced from of the array of nozzle array wherein the grid defines a uniform ground potential, wherein the ground potential of the grid is substantially the same as a potential of the part being printed and the consumable material spaced from the grid.