Abstract: A clad wire feedstock for a directed energy deposition (DED) process is disclosed and includes a core material defining an outer surface and one or more clad metal layers that surround the outer surface of the core material.

Abstract: A build substrate for supporting an article during a directed energy deposition (DED) process includes a clad metal layer defining a build surface, where the article is fused to the build surface during deposition. The build substrate also includes a support substrate configured to support stresses and temperatures experienced during deposition. The support substrate defines an upper surface and a lower surface, and at least a portion of the upper surface of the support substrate is covered with the clad metal layer.

Abstract: A system, method, and three-dimensional printer for contouring a three-dimensional printed part. The system including the three-dimensional printer and processor control system for performing a method of contouring the three-dimensional part. The method including printing a three-dimensionally printed part by depositing a filament in a primary print path with a three-dimensional print head, wherein the three-dimensionally printed part includes a surface oriented in a build direction; and smoothing the surface oriented in the build direction by moving a reflow tool along a smoothing path while printing the three-dimensionally printed part.

Abstract: An ablative support material for providing support to a primary material during a directed energy deposition (DED) process includes an ablative filler including a melting point that is at least about ten percent higher than a melting point of the primary material. The ablative support material is configured to provide mechanical support to the ablative support material during the DED process. The ablative support material includes an amount of the ablative filler that is at least equal to a mechanical percolation threshold of the ablative filler in the polymer binder.

Abstract: A prosthetic socket for a prosthetic limb is provided. The prosthetic socket comprises a socket body and a first and second structural members. The socket body comprises a distal end and a top edge opposite the distal end. The distal end comprises a prosthetic component attachment mechanism. The top edge comprises a medial fin, a lateral fin, a posterior edge and an anterior edge. The first and second structural members each include a first straight portion, a second straight portion, and a first arch portion. The first structural member is disposed on a medial exterior surface of the socket body and the second structural member is disposed on an lateral exterior surface of the socket body.

Abstract: A method of producing XY mechanical test specimens uses material extrusion additive manufacturing. Toolpaths are generated which vary a width of individual beads from a first narrow width in a gage length to a second width greater than the first width in a test specimen grip region. The test specimens produced using additive manufacturing or 3D printing processes reduce a severity of stress concentrators that cause the specimens to fail in the gage length.

Abstract: Tooling formed from a 3D printed scaffold includes a 3D printed scaffold a casting material hardened within the scaffold; and a forming surface defined by the scaffold. A method forming the tooling includes 3D printing a tooling scaffold, wherein the scaffold defines a void volume and a forming surface, filling the void volume with casting material, and hardening the casting material.

Abstract: A system and method for bonding a first layer of material to a second layer of material includes a first electrically conductive plate, a second electrically conductive plate spaced apart from the first electrically conductive plate. The second electrically conductive plate is electrically grounded. A high frequency generator in electrical communication with the first electrically conductive plate supplies high frequency electrical signals to the first electrically conductive plate. An adhesive applied to one of the first and second layers of material has an electromagnetic susceptor material that when subjected to the electric field heats the adhesive to an adhesive curing temperature to bond the first layer of material to the second layer of material. A clamping mechanism applies pressure to one of the first and second layers of material to maintain contact between the first and second layers until an adhesive cure time has lapsed.

Abstract: An emitter and process for plasma fusing of materials. The emitter including a discharge device defining an emitter or an emitter array configured to create a directed plasma to transfer energy to a target object; and a plasma generating electrical system including a power source and two poles, wherein one of said two poles is connected to the target object and the other of said two poles is connected to the discharge device.

Abstract: An antiviral filament and an antiviral three-dimensionally printed component including an antiviral polymer including a base polymer, and an antiviral agent incorporated in the base polymer, wherein the antiviral agent exhibits a phase transition temperature of 200 degrees Centigrade or greater. A method of fabricating a three-dimensional component including feeding an antiviral filament into an extrusion nozzle, the antiviral filament comprising an antiviral polymer; applying heat and pressure to the antiviral filament to melt the antiviral filament in the extrusion nozzle; extruding the antiviral filament from the extrusion nozzle; depositing the extruded antiviral filament into layers; and forming a three-dimensional component from the layers of extruded antiviral filament.

Abstract: A catalytic converter system for a build chamber volume of a three-dimensional printer includes a catalytic converter including a catalyst substrate having a catalytic layer having a predetermined reduction efficiency temperature. The catalytic converter system also includes a blower assembly disposed upstream and in fluid communication with the catalytic converter and the build chamber volume, where the blower assembly circulates exhaust gas from the build chamber volume into the catalytic converter. The catalytic converter system also includes a heater configured to heat the catalyst substrate of the catalytic converter to the predetermined reduction efficiency temperature, and one or more controllers in electronic communication with the blower assembly and the heater. The controller modulates an amount of power provided to the heater and an amount of power provided to the blower assembly.

Abstract: A three-dimensional (3D) printing process utilizing an atmospheric plasma to conduct an electromagnetic energy to fuse extruded successive layers of thermoplastic material having a conductive material is disclosed. A 3D printing system for the 3D printing process is also provided. The 3D printing system includes a 3D printer, an extrusion nozzle, a plasma emitter, and an electromagnetic energy source. The 3D printing process includes the steps of extruding a thermoplastic composite with the extrusion nozzle in successive layers to form a 3D part; directing a substantially evenly distributed plasma onto a predetermined location on the 3D part; and emitting an electromagnetic energy through the plasma. The plasma conducts the electromagnetic energy to the predetermined location on the 3D part. The thermoplastic composite includes a conductive material that generates heat by reacting to the electromagnetic energy.

Abstract: A three-dimensional (3D) printing process utilizing an atmospheric plasma to conduct an electromagnetic energy to fuse extruded successive layers of thermoplastic material having a conductive material is disclosed. A 3D printing system for the 3D printing process is also provided. The 3D printing system includes a 3D printer, an extrusion nozzle, a plasma emitter, and an electromagnetic energy source. The 3D printing process includes the steps of extruding a thermoplastic composite with the extrusion nozzle in successive layers to form a 3D part; directing a substantially evenly distributed plasma onto a predetermined location on the 3D part; and emitting an electromagnetic energy through the plasma. The plasma conducts the electromagnetic energy to the predetermined location on the 3D part. The thermoplastic composite includes a conductive material that generates heat by reacting to the electromagnetic energy.

Abstract: A nozzle assembly for a printer head of a 3D printer includes at least two conduit portions, with each conduit portion including an interfacing surface having a recessed channel that is non-linear. The recessed channels cooperate with one another to define a serpentine path, in response to the interfacing surfaces of the associated conduit portions being engaged to one another. The serpentine path extends from a feed opening to a discharge opening for moving a filament therethrough. The nozzle assembly further includes a heating element connected to the conduit portions for transferring heat to the filament disposed in the serpentine path to fully melt the filament without caramelizing or burning the filament.

Abstract: A three-dimensional printing apparatus for manufacturing a three-dimensional object includes a controller and a three-dimensional printer. The controller has a signal generator. The three-dimensional printer includes a print head, a part carrier, and a plasma field applicator. The plasma field applicator is disposed on an end of the print head. The controller is in communication with the print head, part carrier, and plasma field applicator. The three dimensional printer builds the three-dimensional object onto the part carrier. The signal generator outputs a signal to the plasma field applicator and the plasma field applicator generates an electromagnetic field and induced current pathway incident to the three-dimensional object on the part carrier.

Abstract: A three-dimensional printing apparatus for manufacturing a three-dimensional object includes a controller comprising a signal generator and a three-dimensional printer. The three-dimensional printer includes a print head, a three-dimensional object carrier, and an electrical field applicator. The electrical field applicator is disposed on an end of the print head. The controller is in communication with the print head, part carrier, and electrical field applicator. The three dimensional printer builds the three-dimensional object onto the three-dimensional object carrier. The signal generator outputs a signal to the electrical field applicator and the electrical field applicator generates an electrical field incident to the three-dimensional object on three-dimensional object carrier.

Abstract: A system for manufacturing a multiple layer filament produces a multiple layer filament including a continuous core, a first layer and a second layer. The continuous core includes one of a continuous fiber, a braided strand, a metal wire and a narrow gauge filament. The materials for the first and second layers of the multiple layer filament are chosen from a plurality of materials with each of the plurality of materials providing a specific function or multiple functions that are required for the particular application of the three-dimensional object manufactured using the multiple layer filament.

Abstract: A system and method for bonding a first layer of material to a second layer of material includes a first electrically conductive plate, a second electrically conductive plate spaced apart from the first electrically conductive plate. The second electrically conductive plate is electrically grounded. A high frequency generator in electrical communication with the first electrically conductive plate supplies high frequency electrical signals to the first electrically conductive plate. An adhesive applied to one of the first and second layers of material has an electromagnetic susceptor material that when subjected to the electric field heats the adhesive to an adhesive curing temperature to bond the first layer of material to the second layer of material. A clamping mechanism applies pressure to one of the first and second layers of material to maintain contact between the first and second layers until an adhesive cure time has lapsed.

Abstract: A three-dimensional printer and a method of printing includes feeding a feedstock into a print nozzle including a heated barrel by applying a first extrusion force on the feedstock with a feed system; heating the feedstock in the heated barrel at a first temperature to melt the feedstock; and depositing the melted feedstock onto a support table, wherein the first extrusion force and first temperature are selected to provide a volumetric flow rate in the range of up to 120 cubic millimeters per second.

Abstract: A prosthetic socket for a prosthetic limb is provided. The prosthetic socket comprises a socket body and a first and second structural members. The socket body comprises a distal end and a top edge opposite the distal end. The distal end comprises a prosthetic component attachment mechanism. The top edge comprises a medial fin, a lateral fin, a posterior edge and an anterior edge. The first and second structural members each include a first straight portion, a second straight portion, and a first arch portion. The first structural member is disposed on a medial exterior surface of the socket body and the second structural member is disposed on an lateral exterior surface of the socket body.