Abstract: In additive manufacturing, composite build material filament and release material filament (each a composite of metal/ceramic powder plus binder) are dropped from respective spools to a print head. On the spools and over the drop height, the filaments are heated to a temperature that flexes the filaments but does not soften them to a breaking point, e.g., heated but below a glass transition temperature of a softener (for example, wax) of the binder. The drop height is of similar linear scale to the build plate. The materials are debound and sintered.

Abstract: In printing a sinterable part using a 3D printing model material including a binder and a ceramic or metal sintering material, a release layer intervenes between support structures and the part, each of the support structures and the part formed of the model material. The release layer includes a spherized or powdered higher melting temperature material—ceramic or high temperature metal for example, optionally deposited with a similar (primary) matrix or binder component to the model material. After sintering, the release layer may become a loose powder, permitting the supports to be easily removed.

Abstract: To reduce distortion in an additively manufactured part, a densification linking platform and/or supports of the same composite as the desired part may be printed below the part. After debinding, a resulting shape-retaining brown part assembly is sintered to densify together at a same rate as neighboring metal particles throughout the shape-retaining brown part assembly undergo atomic diffusion. Distortion is reduced by interconnecting portions of the shape-retaining brown part assembly, printing release layers among the portions, depositing adjacent roads of the assembly in retrograde directions, and/or providing channels to accelerate a debinding process.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to applying the filament from the conduit nozzle.

Abstract: A method comprising receiving a first 3D toolpath defining a fill material curved shell, receiving first 2D toolpaths defining support material flat shells, receiving a second 3D toolpath defining a long fiber composite material curved shell, the long fiber composite material including a filament having a matrix embedding fibers having a length longer than two times a diameter of the filament, actuating a fill material deposition head to trace the first 3D toolpath to deposit the fill material curved shell non-parallel to a printing substrate, actuating a support material deposition head to trace the first 2D toolpaths to deposit support material in a succession of substantially flat shells, and actuating a long fiber deposition head to trace the second 3D toolpath non-parallel to the printing substrate to deposit the long fiber composite material curved shell to enclose at least a portion of the fill material curved shell.

Abstract: A three-dimensional geometry is received, and sliced into layers. A first anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material is generated defining at least part of an interior of a first layer. A second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material defines at least part of an interior of a second layer. A generated isotropic fill material tool path defines at least part of a perimeter and at least part of an interior of a third layer intervening between the first and second layers.

Abstract: According to at least one aspect, embodiments of the invention provide a method comprising supplying a reinforced axial fiber filament including a matrix material, a plurality of axial fiber strands extending continuously within the matrix material, and a multiplicity of fiber rods between 0.2-10 mm long dispersed throughout the matrix material, at least some of the dispersed fiber rods being oriented transversely to the fiber strands, supplying a composite fill separately from the filament, including a multiplicity of fiber rods between 0.2-10 mm long dispersed throughout the fill, the fiber rods having hardness at least twice that of a matrix of the fill, and depositing the filament within a first region of an outward portion of a part, through a nozzle throat having a thermal conductivity of at least 35 w/M-K adjacent a nozzle tip having a Rockwell C hardness of at least C40.

Abstract: According to at least one aspect, embodiments of the invention provide a 3D printer comprising an anisotropic head that solidifies, along anisotropic toolpaths, fiber swaths having an anisotropic characteristic oriented relative to a trajectory of the anisotropic tool paths, an isotropic head that solidifies, along isotropic toolpaths, a substantially isotropic material, a motorized drive for moving the anisotropic head and a build plate supporting a printed part in at least three degrees of freedom, and a controller configured to control the 3D printer to build the printed part by solidifying the isotropic material along the isotropic tool paths, solidifying the anisotropic material in fiber swaths tracking a non-concentric set of anisotropic tool paths for at least a first sequence of parallel shells, solidifying the anisotropic material in fiber swaths tracking an outer concentric set of anisotropic tool paths for at least a second sequence of parallel shells.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to applying the filament from the conduit nozzle.

Abstract: In a 3D composite printer, toolpaths defining fill material shells are received, as are toolpaths defining support material shells. A 3D toolpath defining a long fiber composite material curved shell is also received. A fill material deposition head traces the toolpaths to deposit some of the fill material shells or support material shells at least in part non-parallel to a printing substrate. A long fiber deposition head traces the 3D toolpath at least in part non-parallel to the printing substrate to deposit the long fiber composite material curved, concave, ring, tube, or winding shells to enclose, surround, or envelop at least a portion of the fill or support material shells.

Abstract: According to aspects, provided is a method for displaying a three-dimensional geometry of a part to be 3D printed, comprising receiving the geometry of a part sliced into shells or layers, displaying the shells or layers, displaying, for a shell or layer, a representation of a distribution of a isotropic fill material, displaying, for an anisotropic fill subset of the set of shells or layers, a representation of a distribution of an anisotropic fill material having an anisotropic characteristic oriented relative to a trajectory of an anisotropic fill tool path, receiving a selection, from among the displayed shells or layers, of an editing subset, the editing subset including part of the anisotropic fill subset, and regenerating, for a shell or layer of the editing subset, one of a second representation of a distribution of isotropic fill material and a second representation of a distribution of anisotropic fill material.

Abstract: A method and electrical connection for providing electrical power is disclosed. The electrical connection comprises an electrical connector connected to an electrical conductor assembly. A current greater than a rated current capacity of at least one of the electrical connector and electrical conductor assembly may be passed through the electrical conductor assembly and electrical connector. The electrical connector and electrical conductor may be actively cooled with a flow of heat transfer medium flowing substantially along a length of the electrical conductor assembly and through the electrical connector to increase the current capacity of the electrical connection.

Abstract: A three dimensional printer which prints at using at least one composite material having an inherently abrasive filler or fiber material has a Mohs hardness greater than substantially 1, or a Knoop/Vickers hardness greater than substantially 300 kg/mm2, or a Rockwell C hardness at least C30, and where a nozzle tip may contact a top surface of a previously deposited line of material may have a nozzle body includes a material having a thermal conductivity at least 35 w/M-K to conduct heat to the nozzle, and a nozzle throat and/or nozzle tip each include a material having a Rockwell C hardness at least C40, to resist wear from sliding contact of the nozzle tip with the previously deposited lines of the material being printed or another previously deposited material, or from the material being printed as it is printed through the nozzle throat.

Abstract: A three-dimensional geometry is received, and sliced into layers. A first anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material is generated defining at least part of an interior of a first layer. A second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material defines at least part of an interior of a second layer. A generated isotropic fill material tool path defines at least part of a perimeter and at least part of an interior of a third layer intervening between the first and second layers.

Abstract: A three-dimensional geometry is received, and sliced into layers. A first anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material is generated defining at least part of an interior of a first layer. A second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material defines at least part of an interior of a second layer. A generated isotropic fill material tool path defines at least part of a perimeter and at least part of an interior of a third layer intervening between the first and second layers.

Abstract: Combined continuous/random fiber reinforced composite filament including a plurality of axial fiber strands extending substantially continuously within a matrix material of the fiber reinforced composite filament as well as a multiplicity of short chopped fiber rods extending at least in part randomly within the same matrix material is 3D printed via a deposition head including a conduit continuously transitioning to a substantially rounded outlet tipped with an ironing lip, which is driven to flatten the fiber reinforced composite filament against previously deposited portions of the part, as the matrix material and included therein a first proportion of the short chopped fiber rods are is flowed interstitially among the axial fiber strands spread by the ironing lip. A second proportion of the short chopped fiber rods is forced against previously deposited portions of the part.

Abstract: A reinforced molding is formed having an internal continuous fiber reinforcement preform embedded therein. Continuous reinforcing fiber is deposited in a reinforcement volume to form a continuous fiber reinforcement preform, and the reinforcement preform is then located within a mold of a molding apparatus. The mold is loaded with flowable and substantially isotropic molding material, e.g., by injection with heated and/or pressurized resin. The molding material is hardened (by curing or cooling or the like) to overmold the continuous fiber reinforcement preform. The resulting reinforced molding surrounds the internal continuous fiber reinforcement preform with a hardened substantially isotropic molding material.

Abstract: In molten metal jetting, where droplets of metal are jetted to 3D print a part, each layer may be traversed each successive layer with a normalizing grinding wheel or other leveling device such as a layer to level each successive layer, and/or the melt reservoir or printing chamber may be filled with an anoxic gas mix to prevent oxidation.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to applying the filament from the conduit nozzle.