Abstract: A three-dimensional object printer includes a controller that operates at least one ejector to place a layer of photopolymer material on a substrate. The controller is configured to cure the ejected photopolymer layer partially and position fiber on the cured layer before continuing to eject photopolymer material onto the fibers. The fibers can be loose or organized into a mesh. The pieces of mesh position on a cured layer can be pre-cut or a cutting device can be operated to cut pieces of mesh having a shape that corresponds to the shape of the layer of photopolymer material. The fibers reinforce the layers of photopolymer material and add strength and durability to the overall part being formed with the photopolymer material.

Abstract: A three-dimensional object printer includes at least one ejector that is operated to form an uppermost layer of photopolymer material on a substrate. The ejected uppermost photopolymer layer is partially cured and a portion of mesh sheet is positioned on the partially cured layer before the at least one eject continues to eject photopolymer material onto the uppermost layer. The portion of the mesh sheet reinforces the layers of photopolymer material and adds strength and durability to the overall part being formed with the photopolymer material.

Abstract: A controller operates a first actuator to produce relative movement between a multi-nozzle extrusion printhead and a support member along a predetermined path for one layer of a three-dimensional printed object. The multi-nozzle extrusion printhead includes a housing with a chamber, a valve assembly having a plurality of passageways, and a planar member having a plurality of nozzles. The passageways of the valve assembly and the nozzles of the planar member are connected to one another in a one-to-one correspondence and valve members of the valve assembly are operated to open and close melted extruded material flow to the nozzles selectively and independently.

Abstract: A method of operating an additive manufacturing system feeds solid extrusion material into a heater using a slip clutch coupled to an actuator of a mechanical driver to supply thermoplastic material into a manifold in an extruder head. The method sets a speed of the actuator so the actuator operates at a rotational speed that is slightly greater than the rotational speed of the mechanical mover. This method helps maintain the pressure of the thermoplastic material in the manifold of the extruder head in a predetermined range no matter how many nozzles are opened in the extruder head.

Abstract: A printer is configured with at least two printheads that are separated from one another in a cross-process direction by an integral multiple of printhead widths. This configuration enables parallel swaths of material to be ejected and then movement of the printheads in the cross-process direction by a distance corresponding to one or more integral numbers of the printhead width enables the area between the swaths to be completed and the area outside of the original swaths printed.

Abstract: A method of operating an additive manufacturing system feeds solid extrusion material into a heater using a slip clutch coupled to an actuator of a mechanical driver to supply thermoplastic material into a manifold in an extruder head. The method sets a speed of the actuator so the actuator operates at a rotational speed that is slightly greater than the rotational speed of the mechanical mover. This method helps maintain the pressure of the thermoplastic material in the manifold of the extruder head in a predetermined range no matter how many nozzles are opened in the extruder head.

Abstract: An additive manufacturing system includes a slip clutch coupled to an actuator of a mechanical driver that feeds solid extrusion material into a heater for supplying thermoplastic material to a manifold in an extruder head. A speed of the actuator can be set to enable the actuator to operate at a rotational speed that is slightly greater than the rotational speed of the mechanical mover. This configuration enables the pressure of the thermoplastic material in the manifold of the extruder head to be in a predetermined range no matter how many nozzles are opened in the extruder head.

Abstract: A multi-nozzle extrusion printhead includes a chamber with an inlet to receive an extrusion material and a plurality of outlets fluidly coupled to the chamber. The printhead also includes a plurality of valves that control flow of extrusion material through the fluid outlets to nozzles in the printhead. Each valve includes a member and an electromechanical actuator configured to move the member to a first position to block a flow of the extrusion material through one of the fluid outlets and nozzles and to a second position to enable the flow of the extrusion material through the fluid outlet and nozzles.

Abstract: An additive manufacturing system operates at least one ejector and an extruder to form three-dimensional objects with photopolymer material and thermoplastic material. The system operates to deposit the two materials in a layer-by-layer manner. The photopolymer material provides high resolution finishes on the objects and the thermoplastic material enables strong and stable formation of internal portions of the objects.

Abstract: A three-dimensional object printer includes a multi-nozzle extruder, at least one extrusion material supply, and a dispenser that provides extrusion material from the extrusion material supply to each of a plurality of channels, each channel supplying extrusion material to at least one nozzle in the multi nozzle extruder. The dispenser includes an inlet to receive extrusion material from at least one extrusion material supply, an outlet configured to direct the extrusion material to a channel in the plurality of channels, and an actuator configured to move the outlet into alignment with each channel in the plurality of channels.

Abstract: A 3D printer including a pin actuated printhead having an orifice through which a material is ejected, a material chamber to hold the material to be ejected, a channel connecting the material chamber to the orifice, a pin chamber, and an actuated pin within the pin chamber, wherein the actuated pin extends through the pin chamber to eject the material from the orifice. The printhead is configured to eject a material with a viscosity of 10,000 cP or more at an elevated temperature. The 3D printer further includes a material delivery system having a filament driver and a filament heater.

Abstract: A method of manufacturing a three-dimensional object comprises: selecting a first ejector in a plurality of ejectors of a three-dimensional object printer with reference to a hardness identifier, the first ejector configured to eject a first material; selecting a second ejector in the plurality of ejectors with reference to a color identifier, the second ejector configured to eject a second material having a hardness that is different than a hardness of the first material; operating the first ejector to eject the first material toward a platen to form an inner portion of the object with the first material; and operating the second ejector to eject the second material toward the platen to form an outer layer of the object with the second material, the outer layer of the object surrounding at least a portion of the inner portion of the object.

Abstract: A three-dimensional object printing system improves the interlayer adhesion of an object. The printing system includes a platform on which a three-dimensional object is built. A material applicator in the printing system expels material to form layers of the object on the platform. The material applicator also includes a heater mounted to an arm that is configured to rotate about the material applicator to position the heater so the heater heats the layer of the object ahead of the material applicator as the material applicator moves relative to the platform.

Abstract: A controller operates a first actuator to produce relative movement between a multi-nozzle extrusion printhead and a support member along a predetermined path for one layer of a three-dimensional printed object. The multi-nozzle extrusion printhead includes a housing with a chamber, a valve assembly having a plurality of passageways, and a planar member having a plurality of nozzles. The passageways of the valve assembly and the nozzles of the planar member are connected to one another in a one-to-one correspondence and valve members of the valve assembly are operated to open and close melted extruded material flow to the nozzles selectively and independently.

Abstract: A method of operating a multi-nozzle extrusion printhead includes operating with a controller a first actuator to produce relative movement between the printhead and an image receiving surface along a predetermined path for one layer of a three-dimensional printed object. The method further includes first printing an outline of a given layer and then printing the interior of the given layer using a plurality of extrusion nozzles. The method further optionally includes extruding material through a portion of the plurality of nozzles and turning on or off individual nozzles to ensure the swaths printed in the interior conform to the profile of the outline.

Abstract: A three-dimensional object printer uses stereolithography to form a structure and then embed one or more objects in the structure. The printer includes a controller that operates a source of ultraviolet (UV) radiation to cure a portion of a liquid photopolymer at an interface between the liquid photopolymer and the external surface of an embedded object with reference to a meniscus formed between the liquid photopolymer and the external surface of an embedded object. The incorporation of the embedded object speeds formation of the final object and increases the durability of the final object.

Abstract: A three-dimensional object printing system improves the interlayer adhesion of an object. The printing system includes a platform on which a three-dimensional object is built. A material applicator in the printing system expels material to form layers of the object on the platform. The material applicator also includes a heater configured to heat the layer of the object ahead of the material applicator when the material applicator moves in a first direction and a second direction, both directions being parallel to the platform.

Abstract: A printer is configured with at least two printheads that are separated from one another in a cross-process direction by an integral multiple of printhead widths. This configuration enables parallel swaths of material to be ejected and then movement of the printheads in the cross-process direction by a distance corresponding to one or more integral numbers of the printhead width enables the area between the swaths to be completed and the area outside of the original swaths printed.

Abstract: A printer is configured with at least two printheads that are separated from one another in a cross-process direction by an integral multiple of printhead widths. This configuration enables parallel swaths of material to be ejected and then movement of the printheads in the cross-process direction by a distance corresponding to one or more integral numbers of the printhead width enables the area between the swaths to be completed and the area outside of the original swaths printed.

Abstract: A method of manufacturing a three-dimensional object comprises: selecting a first ejector in a plurality of ejectors of a three-dimensional object printer with reference to a hardness identifier, the first ejector configured to eject a first material; selecting a second ejector in the plurality of ejectors with reference to a color identifier, the second ejector configured to eject a second material having a hardness that is different than a hardness of the first material; operating the first ejector to eject the first material toward a platen to form an inner portion of the object with the first material; and operating the second ejector to eject the second material toward the platen to form an outer layer of the object with the second material, the outer layer of the object surrounding at least a portion of the inner portion of the object.