Abstract: A method for printing a three-dimensional part with an additive manufacturing system includes providing a bitslice stack having a plurality of bitslices and printing a plurality of successive layers of the three-dimensional part with the additive manufacturing system based on the bitslices in the bitslice stack. The method includes measuring density of the three-dimensional part under construction near an intermediate build surface after one or more of the successive layers are printed. The method includes determining differences across the intermediate build surface of the measured density to a targeted density to identify one or more density error regions across the intermediate build surface, wherein the density error regions comprise low density regions, and modifying the bitslice stack to compensate for the one or more density error regions.

Abstract: An additive manufacturing system and process for producing three-dimensional parts, which includes forming layers of the three-dimensional part from a part material at a first resolution, and ablating selected voxels of the formed layers with a laser beam at a second resolution that is higher than the first resolution.

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: 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.

Abstract: A payout tube for enabling payout of a consumable filament from a consumable assembly that is configured for use with an additive manufacturing system, the payout tube comprising a tip end having an inlet opening, a base end having an outlet opening, and a tube body having an average effective outer diameter that is substantially greater than an effective inner diameter of the inlet opening.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system includes providing a bitslice stack having a plurality of bitslices and printing a plurality of successive layers of the three-dimensional part with the additive manufacturing system based on the bitslices in the bitslice stack. The method includes measuring density of the three-dimensional part under construction near an intermediate build surface after one or more of the successive layers are printed. The method includes determining differences across the intermediate build surface of the measured density to a targeted density to identify one or more density error regions across the intermediate build surface, wherein the density error regions comprise low density regions, and modifying the bitslice stack to compensate for the one or more density error regions.

Abstract: A method of printing a three-dimensional part includes dividing each of a plurality of layers of a model of the three-dimensional part into a plurality of passes, where each of the plurality of passes is separated from one or more adjacent passes by a gap. The gap between passes in a first layer is offset from the gap between passes in an adjacent layer, such that the gap between passes in the first layer does not align with or stack with the gap between passes in the adjacent layer.

Abstract: A method and system for printing a three-dimensional part, which includes producing a developed layer of a part material with one or more electrophotography engines of an additive manufacturing system, transferring the developed layer from the one or more electrophotography engines to a transfer assembly of the additive manufacturing system sintering the developed layer at the transfer assembly to produce a sintered contiguous film, cooling the sintered contiguous film down to a transfer temperature, and pressing the cooled sintered contiguous film into contact with an intermediate build surface of the three-dimensional part with a low applied pressure.

Abstract: A consumable material and sensor assembly for use in an additive manufacturing system, the consumable material comprising an exterior surface having encoded markings that are configured to be read by the sensor assembly, where the consumable material is configured to be consumed in the additive manufacturing system to build at least a portion of a three-dimensional model.

Abstract: A slot extruder for use with an additive manufacturing system, which includes a plenum configured to receive a photocurable resin, an elongated slot positioned at a bottom end of the plenum and configured to receive the photocurable resin from the plenum, one or more resin inlet ports extending into the plenum, and one or more mechanisms configured to controllably pressurize and depressurize the photocurable resin in the plenum.

Abstract: A method and system for printing a three-dimensional part, which includes printing a plurality of successive layers of the three-dimensional part with the additive manufacturing system based on bitslices in a bitslice stack, measuring surface heights of the successive layers after each of the successive layers are printed, determining differences between the measured surface heights and predicted stack heights of the bitslices, identifying one or more topographical error regions based on the determined differences, and modifying the bitslice stack to compensate for the one or more topographical error regions.

Abstract: A laser assembly for use with an additive manufacturing system, which includes a base block configured to be moved along a scan direction axis in the additive manufacturing system, a plurality of laser emitters preferably arranged in an array of at least two rows of two or more laser emitters. At least a portion of a heat sink assembly is configured to draw heat away from the base block and/or the laser emitters. The assembly includes a controller assembly a controller assembly configured to control a movement of the base block along the first axis and to independently control at least timing and duration of energy emitted from each laser emitter of the plurality of laser emitters as the base block moves along the first axis.

Abstract: A print assembly for use in an additive manufacturing system to print three-dimensional parts, which includes a coarse positioner, a fine positioner, and a liquefier assembly, where a portion of the liquefier assembly is operably mounted to the fine positioner such that the fine positioner is configured to move the portion of the liquefier assembly relative to the coarse positioner.

Abstract: A ribbon liquefier comprising an outer liquefier portion configured to receive thermal energy from a heat transfer component, and a channel at least partially defined by the outer liquefier portion, where the channel has dimensions that are configured to receive the ribbon filament, and where the ribbon liquefier is configured to melt the ribbon filament received in the channel to at least an extrudable state with the received thermal energy to provide a melt flow. The dimensions of the channel are further configured to conform the melt flow from an axially-asymmetric flow to a substantially axially-symmetric flow in an extrusion tip connected to the ribbon liquefier.

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.