Abstract: A method of 3D printing a part with an extrusion-based additive manufacturing system includes providing a filament having a semi-crystalline material as a majority component of a polymeric matrix to a liquefier having a liquefier tube having an overall length between an inlet end and an outlet end. An upper portion of the liquefier tube adjacent the inlet end has a first length and a first cross-sectional area substantially perpendicular to a longitudinal axis and a lower portion of the liquefier tube adjacent the outlet end has a second length and a second cross-sectional area substantially perpendicular to the longitudinal axis, wherein the first cross-sectional area is greater than the second cross-sectional area. The method includes driving the filament into a melt zone located within the upper portion of the liquefier tube at a selected rate based upon a desired extrusion rate. The filament is melted within the melt zone forming a melt pool in the liquefier tube to provide the selected extrusion rate.

Abstract: A method of loading filament into a 3D printer that build parts by fused deposition modeling processes includes providing a 3D printer having a receptacle configured for accepting a plug-in connector from a filament supply. The method further includes providing a filament supply having a container configured to retain a supply of a filament, a filament guide tube having a length, an inlet end attached to the container and an outlet end, and a connector at the outlet end of the filament guide tube. The connector has a geometry allowing it to be plugged into the receptacle and comprises a conduit having an entrance for accepting the outlet end of the filament guide tube and an exit for passing the filament into the printer. The method includes causing a signal to be emitted proximate the receptacle such that when the plug-in connector is inserted into the receptable, light shines through the connector to inform the operator of a filament loading status.

Abstract: A method of 3D printing a part with an extrusion-based additive manufacturing system includes providing a filament having a semi-crystalline material as a majority component of a polymeric matrix to a liquefier having a liquefier tube having an overall length between an inlet end and an outlet end. An upper portion of the liquefier tube adjacent the inlet end has a first length and a first cross-sectional area substantially perpendicular to a longitudinal axis and a lower portion of the liquefier tube adjacent the outlet end has a second length and a second cross-sectional area substantially perpendicular to the longitudinal axis, wherein the first cross-sectional area is greater than the second cross-sectional area. The method includes driving the filament into a melt zone located within the upper portion of the liquefier tube at a selected rate based upon a desired extrusion rate. The filament is melted within the melt zone forming a melt pool in the liquefier tube to provide the selected extrusion rate.

Abstract: A 3D printer includes 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 carrying a first retaining mechanism and a second support member carrying a second retailing mechanism. The first and second retaining mechanisms are both configured to receive and retain the print head or the additional equipment wherein both the removable print head and the removable additional equipment have substantially a same interface with the head carriage.

Abstract: An automated support cleaning system comprising a tank disposed within a housing and configured to circulate an aqueous cleaning solution to remove a support structure from a three-dimensional model.

Abstract: An automated support cleaning system comprising a tank disposed within a housing and configured to circulate an aqueous cleaning solution to remove a support structure from a three-dimensional model.

Abstract: An automated support cleaning system comprising a tank disposed within a housing and configured to circulate an aqueous cleaning solution to remove a support structure from a three-dimensional model.

Abstract: An automated support cleaning system comprising a tank disposed within a housing and configured to circulate an aqueous cleaning solution to remove a support structure from a three-dimensional model.

Abstract: The present invention is a method for performing a calibration routine of a deposition device in a three-dimensional modeling machine that deposits a material to build up three-dimensional objects as directed by a controller on a substrate mounted on a platform. The method comprises generating a material build profile, which represents a three-dimensional structure at defined locations. A relative position of the material build profile is then determined. An expected build profile is identified and then compared to the determined relative position of the material build profile to identify any difference which represents an offset. The modeling system then positions the deposition device based upon the offset.

Abstract: An extrusion head comprising at least one drive wheel and an assembly positionable between at least a first state and a second state. The assembly comprises a first extrusion line configured to engage the at least one drive wheel while the assembly is positioned in the first state, and a second extrusion line configured to engage the at least one drive wheel while the assembly is positioned in the second state.

Abstract: A cassette for use in delivering a continuous length of filament. The cassette includes a housing having a first aperture and a spool rotatably mountable in the cassette housing. The spool contains a first female receptacle alignable with the first aperture, and a flexible boot is attached to the cassette housing and aligned with the first aperture. A removable plug is insertable through the first aperture and into the flexible boot for receipt within the first female receptacle of the spool to prevent rotation of the spool within the cassette housing.

Abstract: A modeling apparatus includes a platform and a substrate, which are adapted to be releasably locked together to provide a surface for building up models in an additive-process three-dimensional modeling machine. The substrate comprises a substantially rigid, non-dusting tray providing a modeling surface. Male connectors extending from the tray are seated in female connectors in the platform, to engage the substrate to the platform. The engaged substrate is locked to the platform, maintaining accurate positioning of the substrate while a model is built. After modeling is complete, the substrate is released from the platform, the model is removed, and the substrate may be reused.