Abstract: A method and program for printing a three-dimensional part with an additive manufacturing system, the method including generating or otherwise providing strain data from a digital model of the three-dimensional part, orienting the digital model to align the directions of high tensile strain in a build plane, and printing the three-dimensional part in a layer-by-layer manner based on the oriented digital model with the additive manufacturing system.

Abstract: A liquefier assembly for use in an additive manufacturing system to print three-dimensional parts. In one aspect, the liquefier assembly includes a liquefier that is transversely compressible, and having an inlet end configured to receive a consumable material in a solid or molten state and an outlet end, a nozzle at the outlet end, and an actuator mechanism configured to transversely compress and expand the liquefier in a controlled manner In another aspect, the liquefier assembly is self heating.

Abstract: A method to form a part in an additive manufacturing system includes providing a melt pool configured to retain and dispense an electrically resistive consumable material and an array of channels in fluid communication with the melt pool. The method includes providing an array of channels in fluid communication with the melt pool, where each of the array of channels have a hollow electrically conductive nozzles wherein each of the array of nozzles is coupled to a distal end of one of the array of channels such that the consumable material can flow from the melt pool to each of the nozzles. The method includes providing a grid spaced from of the array of nozzle array wherein the grid defines a uniform ground potential, wherein the ground potential of the grid is substantially the same as a potential of the part being printed and the consumable material spaced from the grid.

Abstract: In a method of producing a 3D part using an electrophotography-based additive manufacturing system, a plurality of layers of a powder-based material are developed using at least one electrophotography (EP) engine. The developed layers are transferred to a transfer medium. The layers on the transfer medium are dried by heating the layers without fully fusing the powder-based material to itself using a dryer. This reduces a water content of the layers. The dried layers are heated on the transfer medium to at least a fusion temperature, at which the power-based material fuses together, using a pre-transfusion heater. The dried layers are then transfused together on a build platform using a transfusion assembly to build the part in a layer-by-layer manner.

Abstract: A method and system for printing a three-dimensional part, which includes rotating a transfer belt with a developed layer, scanning the developed layer on the rotating transfer belt, pressing the developed layer into contact with an intermediate build surface of the three-dimensional part retained on a moveable build platform, scanning the pressed layer on the three-dimensional part, comparing the scanned layers to detect an overlay error, and adjusting a position of the moveable build platform relative to the transfer belt to reduce the overlay error for a subsequent developed layer.

Abstract: A method of printing a part in an additive manufacturing system includes printing a support structure for the part, printing a boundary surrounding the support structure, and printing the part on the support structure. An additive manufacturing system for printing a three-dimensional part includes a transfer medium configured to receive and transfer imaged layers of a thermoplastic-based powder for a boundary, a thermoplastic-based powder for a support, and a thermoplastic-based powder for the part from at least two imaging engines, a heater configured to heat the imaged layers on the transfer medium to at least a fusion temperature of the thermoplastic-based powder, and a layer transfusion assembly including a build platform, the layer transfusion assembly being configured to transfuse the heated layers in a layer-by-layer manner onto the build platform to print the three-dimensional part.

Abstract: A method of additive three-dimensional object production includes depositing liquefied material to produce two roads and placing an extruder tip having a bottom surface that surrounds an orifice such that one portion of the bottom surface is sealed against one of the two roads and another part of the bottom surface is sealed against the other of the two roads and the orifice is positioned over a space between the two roads. Liquefied material is then extruded through the orifice to fill the space between the two roads.

Abstract: A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.

Abstract: A filament feeding device includes a drive mechanism and a displacement sensor. The drive mechanism is configured to feed a filament along a feed path. The displacement sensor is positioned adjacent the feed path and is configured to determine a velocity and direction in which the filament is fed along the feed path based on at least two capacitance measurements that vary in response to movement of the filament along the feed path.

Abstract: A continuous liquid interface production system includes a source of optical stimulation. The system includes a vessel configured to retain a pool or film of optically sensitive monomer and a substantially optically transparent plate retained by the vessel. The optical stimulation is directed through the plate and into the pool or the film based upon a sliced 3D model of the part. The system includes source of reaction inhibitor wherein the substantially optically transparent plate allows the reaction inhibitor to permeate through the plate and into the pool or the film such that a sufficient amount of reaction inhibitor is within the pool or the film to create a zone proximate the plate that prevents polymerization therein.

Abstract: An additive manufacturing system for printing a three-dimensional part, which includes one or more electrophotography engines configured to develop layers of the three-dimensional part, a rotatable transfer belt configured to receive the developed layers from the electrophotography engine(s), a detector configured to measure powder densities of the developed layers on the rotatable transfer belt, and to transmit signals relating to the measured powder densities to a controller assembly, and a printing assembly configured to receive the developed layer from the rotatable transfer belt and to print the three-dimensional part from the developed layers.

Abstract: A pump assembly for use in an additive manufacturing system includes a viscosity pump having a first end and a second end wherein the first end has a cross sectional area greater than a cross sectional area of the second end. The viscosity pump has a conical shaped inner surface defining a pump chamber, an inlet proximate the first end and an outlet proximate the second end. The viscosity pump includes an impeller having an axis of rotation, where the impeller has a shaft positioned through the first end of the first housing and into the pump chamber. The impeller includes a distal tip-end at a distal end of the shaft wherein the impeller is configured to be axially displaced within the pump chamber of the viscosity pump parallel to the axis of rotation. An actuator is coupled to a proximal end of the impeller, wherein the actuator is configured to move the impeller parallel to the axis of rotation.

Abstract: A method and program for printing a three-dimensional part with an additive manufacturing system, the method including generating or otherwise providing strain data from a digital model of the three-dimensional part, orienting the digital model to align the directions of high tensile strain in a build plane, and printing the three-dimensional part in a layer-by-layer manner based on the oriented digital model with the additive manufacturing system.

Abstract: An additive manufacturing system that retains a print head for printing a three-dimensional part in a layer-by-layer manner using an additive manufacturing technique, where the retained print head is configured to receive a consumable material, melt the consumable material, and extrude the molten material. The system also includes a velocimetry assembly configured to determine flow rates of the molten material, and a controller assembly configured to manage the extrusion of the molten material from the print head, and to receive signals from the velocimetry assembly relating to the determined flow rates.

Abstract: A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.

Abstract: A method for building a three-dimensional object containing an identification-tag insert, the method comprising performing a build operation to form layers of the three-dimensional object using a layer-based additive technique, placing the identification-tag insert on at least a portion of the layers during the build operation, and reading information from the identification-tag insert.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system, the liquefier assembly comprising a downstream portion having a first average inner cross-sectional area, and an upstream having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion defining a shoulder configured to restrict movement of a melt meniscus of a consumable material.

Abstract: An additive manufacturing system that retains a print head for printing a three-dimensional part in a layer-by-layer manner using an additive manufacturing technique, where the retained print head is configured to receive a consumable material, melt the consumable material, and extrude the molten material. The system also includes a velocimetry assembly configured to determine flow rates of the molten material, and a controller assembly configured to manage the extrusion of the molten material from the print head, and to receive signals from the velocimetry assembly relating to the determined flow rates.

Abstract: A magnetically throttled liquefier assembly for use in an additive manufacturing system and configured to heat a metal-based alloy to an extrudable state includes an array of magnets to generate a magnetic field in order to induce a viscosity in the heated metal-based alloy and to control the flow rate of the heated metal-based alloy through the liquefier for extrusion and the building of a three-dimensional object with the metal-based alloy.

Abstract: In a method for printing a three-dimensional (3D) parts with an additive manufacturing system, a developed layer of an electrically charged powder material is produced on a transfer medium using an electrophotographic (EP) engine. The transfer medium and the developed layer are fed in a feed direction. A position of the developed layer on the transfer medium is detected using a first sensor having a first output that indicates the position. A position of a moveable build platform is adjusted relative to the transfer medium to reduce one or more overlay errors between the developed layer and an intermediate build surface of a three-dimensional structure retained on the moveable build platform based on the first output. The developed layer is transferred to the intermediate build surface using a pressing element.