Abstract: A method for identifying an angle of roll for a multi-nozzle extruder includes moving the extruder in a first process direction to form a first set of swaths of extrusion material using two nozzles in the extruder and moving the extruder in a second process direction to form a second set of swaths of extrusion material. The method further includes identifying a location of one nozzle relative to the other nozzle in two dimensions based on cross-process direction distances between the first and second sets of swaths and identifying the angle of extruder roll for the extruder based on the location of the one nozzle and a predetermined geometry of the extruder.

Abstract: A method for identifying an angular deviation in the orientation of a multi-nozzle extruder includes moving the multi-nozzle extruder in a first process direction to form a first extrusion material swath and moving the multi-nozzle extruder in a second process direction opposing the first process direction to form a second extrusion material swath. The method further includes identifying widths and heights of the swaths from scanned image data and identifying a component of angular deviation for the multi-nozzle extruder with reference to at least one of a difference between the first swath width and the second swath width and another difference between the first swath height and the second swath height.

Abstract: A three-dimensional object printer generates image data of an object being formed in the printer with an optical sensor and identifies the heights of object features above a substrate on which the object is being formed. A controller operates one or more actuators to move the optical sensor at a plurality of distances above the object to generate image data of the object at a plurality of heights above the object. The controller identifies the distances of the features of the object with reference to the image data generated by the optical sensor and the focal length of the optical sensor.

Abstract: A method of manufacturing a three-dimensional object is disclosed. The method includes operating a first ejector of a three-dimensional object printer to eject a first material towards a platen to form an object. The method further includes operating a second ejector of the three-dimensional object printer to eject a second material towards the platen to form support for portions of the object, the support being configured to provide support for portions of the object during the operation of the first ejector to form the object, at least one portion of the support having a body with at least one fluid path that connects at least one opening in the body to at least one other opening in the body. The method further includes connecting a fluid source to the at least one fluid path of the support to enable fluid to flow through the at least one fluid path to remove at least an inner portion the support from the object.

Abstract: A three-dimensional object printer generates image data of an object being formed in the printer with an optical sensor and identifies the heights of object features above a substrate on which the object is being formed. A controller operates one or more actuators to move the optical sensor at a plurality of distances above the object to generate image data of the object at a plurality of heights above the object. The controller identifies the distances of the features of the object with reference to the image data generated by the optical sensor and the focal length of the optical sensor.

Abstract: A method of spatially and spectrally calibrating a spectrophotometer including: a) emitting a white light illumination output from a full width illumination source; b) illuminating a test patch with the white light illumination output; c) reflecting a portion of the white light illumination output from the test patch to form a white light reflected illumination output; d) receiving the white light reflected illumination output at first, second and third rows of photosensitive elements to form a first calibration data set; e) emitting a cyan light illumination output from the full width illumination source; f) illuminating the test patch with the cyan light illumination output; g) reflecting a portion of the cyan light illumination output from the test patch to form a cyan light reflected illumination output; and, h) receiving the cyan light reflected illumination output at the second and third rows of photosensitive elements to form a second calibration data set.

Abstract: A three-dimensional object printer has a controller that operates pluralities of ejectors ejecting drops of different materials having different colors, at least one color of which is white, to produce objects with different levels of color saturation. The controller operates the pluralities of ejectors with reference to a function of a sum of an average number of drops per voxel in each layer, a target value of an average number of drops per voxel of colorants other than white in each layer, and a distance from a closest surface of the object for each material ejected by the ejectors. At a predetermined distance from a closest surface and greater, the controller operates the pluralities of ejectors to form voxels in layers of the object with only clear and white drops. At distances less than the predetermined distance, the number of clear drops increases and the number of white drops decreases.

Abstract: A method for printing a three-dimensional crystalline structure such as a chocolate layer wherein, after printing, the material has a desired crystal structure and a plurality of non-random cavities. An embodiment can include printing a liquid first layer of material with a printer onto a second layer of material having a crystal structure. Subsequently, the printed liquid first layer is processed to solidify the first layer. During the processing of the printed liquid first layer, the second layer functions as a crystal seed layer through physical contact with the printed liquid first layer and the second layer crystallizes with the crystal structure. In some embodiments, confections may be formed from high-quality chocolate, where the confection has a reduced caloric content with acceptable mouthfeel. In other embodiments, a confection may have a previously unrealized mouthfeel and taste.

Abstract: A three-dimensional object printer generates image data of an object being formed in the printer with an optical sensor and identifies the heights of object features above a substrate on which the object is being formed. A controller operates one or more actuators to move the optical sensor at a plurality of distances above the object to generate image data of the object at a plurality of heights above the object. The controller identifies the distances of the features of the object with reference to the image data generated by the optical sensor and the focal length of the optical sensor.

Abstract: A method of operating an extruder assembly to form a three-dimensional build object forms a build object quickly, with enhanced feature resolution, and with increased structural strength. The method includes positioning with at least one actuator an extruder having at least one opening defining an extrusion area through which build material can be extruded through the at least one opening. The extruder is positioned to cover a first portion of the extrusion area with a portion of an object supported on a build platen and to leave open a second portion of the extrusion area. The method further includes extruding a first continuous ribbon of build material adjacent to the object through the second portion of the extrusion area while moving the extruder along the object with the at least one actuator.

Abstract: A method for operating an inkjet printhead includes identifying a number of ink drop ejections for an inkjet in the printhead to form a printed image with reference to image data corresponding to the printed image and generating control data that specify a sequence of a plurality of non-firing electrical signals to be applied to the inkjet with reference to a predetermined control sequence stored in a memory and the number of ink drop ejections. The method further includes generating non-firing electrical signals applied to the inkjet with reference to the control data and generating a plurality of firing electrical signals applied to the inkjet to eject ink drops after generating every non-firing electrical signal in the plurality of non-firing electrical signals.

Abstract: An additive manufacturing system has a plurality of manifolds in an extruder. Each manifold is connected to at least one nozzle of the extruder to enable the at least one nozzle to extrude thermoplastic material through a corresponding aperture in a faceplate mounted to the extruder. A plurality of valves is configured between each manifold and each nozzle connected to the manifold to enable the nozzles connected to a manifold to extrude thermoplastic material from the manifold selectively. The faceplate is also configured for rotation about an axis perpendicular to the faceplate to enable different orientations of the nozzles in the apertures of the faceplate. The different manifolds of the extruder enable a plurality of thermoplastic materials having a different property to be extruded simultaneously so the materials can join to one another while the materials are at an elevated temperature.

Abstract: An apparatus changes the temperature of thermoplastic material in an extruder head to reduce the time for producing an object. The apparatus includes a cooling device located near the one or more nozzles of the extruder head to change the temperature of the thermoplastic material extruded by the extruder head. The apparatus cools the thermoplastic material to enhance the formation of exterior object features. A heater can also be positioned near the nozzle zone to heat the thermoplastic material to reduce the time for raising the viscosity of the thermoplastic material for forming interior regions of the object.

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: An apparatus includes a heater for converting a filament of extrusion material into thermoplastic material. The heater has a channel configured to change the cross-sectional shape of the filament to a cross-sectional shape that has a greater surface area than the surface area of the filament before the heater receives the filament. The channel of the heater can also be configured to drive the center portion of the filament toward the heated walls of the channel and to mix thermoplastic material in the channel while exposing the center portion of the filament to the heated wall of the channel.

Abstract: A method for operating a three-dimensional object printer compensates for inoperative ejectors. The method identifies image data values associated with an inoperative ejector that stored in a memory with other image data values for a three-dimensional object to be printed by the three-dimensional object printer. The method replaces the image data values associated with the inoperative ejector with image data values associated with an operative ejector that correspond to a material that is different than a material ejected by the inoperative ejector and operates a plurality of ejectors with reference to the other image data values and the replaced image data values to enable the operative ejector to eject drops of the material that is different than the material ejected by the inoperative ejector into the three-dimensional object at positions where the inoperative ejector would have ejected material.

Abstract: A method for compensating for inoperative ejectors in a three-dimensional object printer has been developed. A printer detects an inoperative ejector in a printhead. The printer identifies functional ejectors that print at locations adjacent to locations where the inoperative ejector fails to print a drop. The printer modifies firing signals for the functional ejectors so those ejectors print drops having an increased drop volume at the locations adjacent to locations where the inoperative ejector fails to print a drop. The printer prints a first layer of material drops using the modified firing signals. The printer advances the printhead in the cross-process direction between layers so that locations where the inoperative ejector fails do print a drop do not coincide between layers.

Abstract: A method of operating an extruder assembly to form a three-dimensional build object forms a build object quickly, with enhanced feature resolution, and with increased structural strength. The method includes positioning with at least one actuator an extruder having at least one opening defining an extrusion area through which build material can be extruded through the at least one opening. The extruder is positioned to cover a first portion of the extrusion area with a portion of an object supported on a build platen and to leave open a second portion of the extrusion area. The method further includes extruding a first continuous ribbon of build material adjacent to the object through the second portion of the extrusion area while moving the extruder along the object with the at least one actuator.

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 three-dimensionally printed object includes a plurality of different material regions that together define a surface region of the object. The plurality of different material regions includes a first material region and a second material region. The first material region has a first color, and the second material region has a second color that is different from the first color. The different material regions overlap from each other within the object by different amounts viewed from different directions so that different proportions of light from the plurality of different material regions are visible to an observer viewing the surface region of the three-dimensionally printed object from different view directions, different view angles, and with illumination lighting the surface region at different angles. A coloration of the surface region is altered based on the proportions of light from the plurality of different material regions visible to the observer.