Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering.

Abstract: Systems and methods for making it easier to remove support structures printed in conjunction with printing an object using stereolithographic additive manufacturing are disclosed. In some exemplary embodiments, one or more interfaces between the printed object and the support structures are modulated to allow for easy separation between them, in some instances even when the object and support structures are made from the same material. Various modulation techniques are disclosed, including adjusting an intensity of exposure to light at interfaces between the object and support structures, and using two materials where one material cures at two wavelength ranges and the other material only cures at one of the two wavelength ranges. Other systems and methods that allow for easy separation of part and support structure are also described.

Abstract: Systems and methods for additive manufacturing are generally disclosed. Additive manufacturing may be performed in a continuous manner and/or semi-continuous manner by transporting one or more build plates relative to printheads that comprise a plurality of energy source arrays and/or binderjet arrays that may be selectively activated to form a desired pattern in a material layer disposed on the one or more build plates.

Abstract: According to some aspects, techniques are provided for fabricating sinterable metallic parts through the application of directed energy to a build material. In particular, applying energy to a build material comprising a polymer mixed with a metal powder may cause the polymer to form a cohesive structure with the metal powder. As a result, the polymer acts as a “glue” to produce a metallic green part without local melting of the metal. The green part may subsequently be sintered to remove the polymer and produce a fully dense metal part. Optionally, a step of debinding may also be performed prior to, or simultaneously with, sintering.

Abstract: The present invention provides methods for uniform growth of nanostructures such as nanotubes (e.g., carbon nanotubes) on the surface of a substrate, wherein the long axes of the nanostructures may be substantially aligned. The nanostructures may be further processed for use in various applications, such as composite materials. For example, a set of aligned nanostructures may be formed and transferred, either in bulk or to another surface, to another material to enhance the properties of the material. In some cases, the nanostructures may enhance the mechanical properties of a material, for example, providing mechanical reinforcement at an interface between two materials or plies. In some cases, the nanostructures may enhance thermal and/or electronic properties of a material. The present invention also provides systems and methods for growth of nanostructures, including batch processes and continuous processes.

Abstract: A novel cutting-edge structure and method and apparatus for manufacturing the cutting-edge structure is provided. The cutting-edge structure is comprised of naturally derived or renewable material at greater than 50% by volume fraction. In one embodiment, the naturally derived material is a cellulose nanostructure such as a cellulose nanocrystal. The cellulose nanocrystal is processed using a base or mold structure to provide a cutting edge of any shape such as linear or circular edge structures. The process includes dual cure steps to produce an optimal cutting-edge structure without shrinkage. The formed cutting-edge structure can be utilized as a razor blade as it is formed with very sharp tip and edge suitable for cutting hair. The base structure can form one or more cutting-edge structures simultaneously.

Abstract: A device for collecting contaminants from water samples is provided. The device includes a solid sorbent that collects and stores the contaminants from water samples. The solid sorbent is configured to allow for the preservation of the stored contaminants. The concentrations of the contaminants in the water samples are determined via analysis of the solid sorbent or via elution of the stored contaminants from the sorbent and analysis of the eluate solution.

Abstract: Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Abstract: The present disclosure is directed to rheometric fixtures for making rheological measurements of yield stress fluids. In some embodiments, the fixture can be an improvement of a typical vane by having the ability to create a more homogeneous shear profile in a test material, e.g., a yield stress fluid. These vane fixtures having fractal-like cross-sectional structures enable robust rheological measurements of the properties of yield stress fluids due to several outer contact edges that lead to increased kinematic homogeneity at the point of yielding and beyond. The branching structure of the fractal-like fixtures can alter the shape of a wetted perimeter of the fixture while minimizing an area thereof to allow the fixture to be inserted into fluids with less disturbance. In some embodiments, a cup with a ribbed inner surface can be used to hold the sample fluid and disassembles for ease of cleaning following completion of the measurement.

Abstract: The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

Abstract: Systems, devices, and methods for additive manufacturing are provided that allow for components being manufactured to be assessed during the printing process. As a result, changes to a print plan can be considered, made, and implemented during the printing process. More particularly, in exemplary embodiments, a spectrometer is operated while a component is being printed to measure one or more parameters associated with one or more layers of the component being printed. The measured parameter(s) are then relied upon to determine if any changes are needed to the way printing is occurring, and if such changes are desirable, the system is able to implement such changes during the printing process. By way of non-limiting examples, printed material in one or more layers may be reheated to alter the printed component, such as to remove defects identified by the spectrometer data.

Abstract: A novel cutting-edge structure and method and apparatus for manufacturing the cutting-edge structure is provided. The cutting-edge structure is comprised of naturally derived or renewable material at greater than 50% by volume fraction. In one embodiment, the naturally derived material is a cellulose nanostructure such as a cellulose nanocrystal. The cellulose nanocrystal is processed using a base or mold structure to provide a cutting edge of any shape such as linear or circular edge structures. The process includes dual cure steps to produce an optimal cutting-edge structure without shrinkage. The formed cutting-edge structure can be utilized as a razor blade as it is formed with very sharp tip and edge suitable for cutting hair. The base structure can form one or more cutting-edge structures simultaneously.

Abstract: The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

Abstract: According to some aspects, techniques are provided for fabricating sinterable metallic parts through the application of directed energy to a build material. In particular, applying energy to a build material comprising a polymer mixed with a metal powder may cause the polymer to form a cohesive structure with the metal powder. As a result, the polymer acts as a “glue” to produce a metallic green part without local melting of the metal. The green part may subsequently be sintered to remove the polymer and produce a fully dense metal part. Optionally, a step of debinding may also be performed prior to, or simultaneously with, sintering.

Abstract: Systems, devices, and methods for detecting contamination (e.g., bacteria) in fluid are provided. The systems, devices, and methods allow for filtering a fluid sample using a filter to capture and concentrate cells (e.g., bacteria) to detect electrochemical properties thereof. The cells can be exposed to a reagent that diffuses into the cells to produce a product of interest that can be used in analysis of the fluid sample. The product of interest can diffuse out of the filter into a fluid storage component for detection and analysis by an analysis component. After the sampling is completed, the filter can be detached and discarded. Other aspects of the present disclosure, including enhancements and various systems and methods for concentrating cells and analyzing the same, are also provided.

Abstract: Wearable and implantable devices that are used to support human anatomy and are formed using additive manufacturing are provided. Systems and methods for performing additive manufacturing allow for the formulation of a mesh material that has localized stiffness and slack in regions to best serve the needs of the patient. For example, regions of the mesh material can be designed to rigidly support portions of human anatomy, such as injured tissue, while regions of the mesh material adjacent to the injured tissue can be designed to closely mimic movement of the relevant human anatomy. For example, the mesh material can be formed in a manner such that it does not fold in those regions, and therefore is not obtrusive. The present disclosure allows for control of toolpaths when printing fibers used to form the devices. Other devices, as well as systems and methods for creating the same, are also provided.

Abstract: Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Abstract: Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.

Abstract: Disclosed are methods for building colloidal solids by precipitation from a liquid bridge using a needle through which a colloidal particle suspension is dispensed onto a substrate in a temperature-controlled environment. The substrate can rest on a motion-controlled stage, and freeform shapes can be built by coordinating the motion of the stage with the rate of dispense of colloidal particle suspension. Aspects include a scaling law that governs the rate of assembly and a direct-write colloidal assembly process that combines self-assembly with direct-write 3D printing, and can be used to build exemplary freestanding structures using a diverse materials, such as polystyrene, silica and gold particles. Additionally, disclosed are methods for predicting and eliminating cracking by a geometric relationship between particle size and structure dimensions, enabling the production of macroscale, crack-free colloidal crystals.

Abstract: Disclosed are systems, devices, and methods for additive manufacturing that allow for control of composition and/or porosity of components being manufactured. More particularly, in exemplary embodiments, a secondary material can be used in conjunction with a primary feedstock material in a spatially controlled manner during an additive manufacturing process to control a composition of materials and/or porosity of a manufactured component. Systems, devices, and methods for additive manufacturing are also disclosed that allow for control of a pressure of an atmosphere surrounding a build surface during an additive manufacturing process. More particularly, a pressure of an atmosphere surrounding a build surface can be raised to a pressure greater than standard atmospheric pressure. Various features of the exemplary embodiments of the systems, devices, and methods disclosed can be used together to further control for composition and/or porosity and quality of a manufactured part.