Abstract: Disclosed herein is a system for printing a three-dimensional object. The system can include at least one nozzle assembly configured to receive a continuous fiber and at least partially encase the continuous fiber with a polymer material to create a composite material. The nozzle assembly can also include a liquefier assembly that is operable coupled to a nozzle, which is configured to allow for the controlled deposit of the composite material while minimizing or eliminating tension exerted on the continuous fiber.

Abstract: Disclosed herein is a system for printing a three-dimensional object. The system can include at least one nozzle assembly configured to receive a continuous fiber and at least partially encase the continuous fiber with a polymer material to create a composite material. The nozzle assembly can also include a liquefier assembly that is operable coupled to a nozzle, which is configured to allow for the controlled deposit of the composite material while minimizing or eliminating tension exerted on the continuous fiber.

Abstract: A composite filament for use in additive manufacturing such as fused filament fabrication is described along with methods of its construction and use. The composite filament includes a single continuous filament (e.g., a continuous carbon roving) and a polymer (e.g., a high glass transition polymer) in intimate contact. The composite filament is formed through immersion of the continuous filament in a solution of the polymer. The composite filament can be combined with an additional formation material in an additive manufacturing process.

Abstract: A part includes a continuous fiber substantially encased in a formation material. The fiber and formation material are arranged in a plurality of alternating layers such that the formation material of a first one of the alternating layers adheres to the formation material of a second one of the alternating layers over the length of the continuous fiber. The part may include a thin-walled hollow member such as a duct. In some embodiments a part comprises a continuous fiber prepared by an additive manufacturing process comprising the steps of: depositing a composite material on a print bed using a print head, the composite material comprising a continuous fiber and a formation material in intimate contact with the continuous fiber; moving the print head and/or the print bed during the depositing of the composite material; and consolidating the composite material.

Abstract: Disclosed herein is a system for printing a three-dimensional object. The system can include at least one nozzle assembly configured to receive a continuous fiber and at least partially encase the continuous fiber with a polymer material to create a composite material. The nozzle assembly can also include a liquefier assembly that is operable coupled to a nozzle, which is configured to allow for the controlled deposit of the composite material while minimizing or eliminating tension exerted on the continuous fiber.

Abstract: A part includes a continuous fiber substantially encased in a formation material. The fiber and formation material are arranged in a plurality of alternating layers such that the formation material of a first one of the alternating layers adheres to the formation material of a second one of the alternating layers over the length of the continuous fiber. The part may include a thin-walled hollow member such as a duct. In some embodiments a part comprises a continuous fiber prepared by an additive manufacturing process comprising the steps of: depositing a composite material on a print bed using a print head, the composite material comprising a continuous fiber and a formation material in intimate contact with the continuous fiber; moving the print head and/or the print bed during the depositing of the composite material; and consolidating the composite material.

Abstract: A composite filament for use in additive manufacturing such as fused filament fabrication is described along with methods of its construction and use. The composite filament includes a single continuous filament (e.g., a continuous carbon roving) and a polymer (e.g., a high glass transition polymer) in intimate contact. The composite filament is formed through immersion of the continuous filament in a solution of the polymer. The composite filament can be combined with an additional formation material in an additive manufacturing process.