Abstract: A 3D printing apparatus and method prints a partial part, and continues to print the part after the partially-printed part has been rotated. Each partial printing operation may include reinforcement via application of one or more layers of continuous fiber. The rotation and continued printing of the partially-printed part allows for fiber orientation in different orientations for the printed part.

Abstract: A 3D printing apparatus and method includes a piezo actuator that reciprocates a tappet. The reciprocation of the tappet generates pressure within a chamber filled with molten print material. The generated pressure causes the molten print material to be extruded through a nozzle coupled to the chamber. The piezo actuator is controlled to switchably provide continuous extrusion of print material or extrusion of discrete droplets of print material.

Abstract: A method of manufacturing a part formed of metal, a method of determining a ceramic support structure for the metal part, and an un-sintered metal part including the ceramic support. The method of manufacturing the part includes forming a metal part and forming a ceramic support by depositing a ceramic composite material in a pattern to form ceramic print layers. The ceramic support supports a supportable portion of the metal part. The method of determining the ceramic support structure for the metal part includes determining, (i) a composition of a ceramic filament used to produce the ceramic support or (ii) a geometry of an infill of the ceramic support such that the ceramic support has a strength sufficient to support the supportable portion prior to sintering and is deformable to allow the supportable portion to undergo geometric changes during sintering.

Abstract: A flexible 3D printing feedstock material is disclosed. The flexible 3D printing feedstock material includes 45-80 vol % of a powder having at least one of a metal powder and a ceramic powder, 0-5 vol % of a compatibilizer, 10-35 vol % of a soluble flexibilizer, and 5-35 vol % of a non-soluble binder component. Methods of forming the flexible 3D printing feedstock material by melt mixing the components are disclosed. Methods of producing a 3D printed part by operating a fused deposition modeling 3D printer loaded with a filament formed of the 3D printing feedstock material are also disclosed.

Abstract: A material for producing a three-dimensionally printed part including a metal material and at least one sintering aid in an amount effective to give the three-dimensionally printed part a density of between about 90% and about 100% after sintering is disclosed. A method of printing a three-dimensional part including selecting a metal material, incorporating at least one sintering aid into the metal material to form a print material, and printing the three-dimensional part is also disclosed. A method of producing a sintered metal part including providing a metal material for the sintered metal part incorporating boron as a first sintering aid, incorporating phosphorus as a second sintering aid, forming the metal part in a predetermined form the metal material, and heating the formed metal part to a sintering temperature is also disclosed. Three-dimensionally printed parts are also disclosed.

Abstract: A 3D printing apparatus and method corrects for skew in the motion components of the apparatus without the use of an independent reference object. A calibration object having features therein or thereon is printed. A user rotates the calibration object by a certain angle after it is printed. The features in/on the calibration object are measured, and an amount of skew is determined based on the measurements. In addition, a 3D printing operation is compensated based on the effects of a coefficient of thermal expansion and/or moisture absorption on dimensional changes.

Abstract: Metal composites, tooling and methods of additively manufacturing these are disclosed. Metal objects and structures as provided herein are additively manufactured from metal having an infill pattern infiltrated with a metal powder. Also provided herein are methods of forming such objects and structures. Methods include additively manufacturing a metal structure having an interior printed using an infill. Steps can further include infiltrating the printed infill of the structure with a powder metal thereby forming a composite.

Abstract: Methods of printing using three dimensional printers are disclosed. The method includes feeding a printable material through a linear feed mechanism to a print head, detecting the printable material is jammed in the three-dimensional printer, and operating, in response to detecting that the printable material is jammed, the three-dimensional printer in a jam clearing mode. The jam clearing mode includes advancing a drive component of the linear feed mechanism, retracting the drive component of the linear feed mechanism, and repeating the advancing and retracting of the drive component of the linear feed mechanism. Three-dimensional printing systems are also disclosed. A three-dimensional printing system includes a print head, a linear feed mechanism operatively coupled to the print head, and a controller operatively coupled to the three-dimensional printing system.

Abstract: Metal composites, tooling and methods of additively manufacturing these are disclosed. Metal objects and structures as provided herein are additively manufactured from metal having an infill pattern infiltrated with a second metal. Also provided herein are methods of forming such objects and structures. Methods include additively manufacturing a metal structure having an interior printed using an infill. Steps can further include infiltrating the printed infill of the structure with a liquid metal thereby forming a bi-metal composite.

Abstract: A material for producing a three-dimensionally printed part including a metal material and at least one sintering aid in an amount effective to give the three-dimensionally printed part a density of between about 90% and about 100% after sintering is disclosed. A method of printing a three-dimensional part including selecting a metal material, incorporating at least one sintering aid into the metal material to form a print material, and printing the three-dimensional part is also disclosed. A method of producing a sintered metal part including providing a metal material for the sintered metal part incorporating boron as a first sintering aid, incorporating phosphorus as a second sintering aid, forming the metal part in a predetermined form the metal material, and heating the formed metal part to a sintering temperature is also disclosed. Three-dimensionally printed parts are also disclosed.

Abstract: A flexible 3D printing feedstock material is disclosed. The flexible 3D printing feedstock material includes 45-80 vol % of a powder having at least one of a metal powder and a ceramic powder, 0-5 vol % of a compatibilizer, 10-35 vol % of a soluble flexibilizer, and 5-35 vol % of a non-soluble binder component. Methods of forming the flexible 3D printing feedstock material by melt mixing the components are disclosed. Methods of producing a 3D printed part by operating a fused deposition modeling 3D printer loaded with a filament formed of the 3D printing feedstock material are also disclosed.

Abstract: Embodiments of the present invention relate to modular devices. The modular device comprises an enclosure having a main body and an extending member. A battery positioned at least within the main body. The extending member includes a coupling element. The coupling element is designed to provide electrical communication with another extending member when the extending member and the other extending member are in communication with each other. The coupling element is designed to provide structural support when in communication with the other extending member. The coupling element is in electrical communication with the battery. The modular device is designed in a manner to couple with another modular device via the coupling element.

Abstract: A high surface area scaffold to be used for a solar cell, made of a three-dimensional percolated network of functionalized graphene sheets. It may be used in the preparation of a high surface area electrode by coating with a semiconductive material. Electronic devices can be made therefrom, including solar cells such as dye-sensitized solar cells.

Abstract: Nano-graphene oxide sheets or nano-graphene sheets having a maximum average lateral dimension of about 50 nm and methods of making nano-graphene oxide sheets and nano-graphene sheets.

Abstract: A high surface area scaffold to be used for a solar cell, made of a three-dimensional percolated network of functionalized graphene sheets. It may be used in the preparation of a high surface area electrode by coating with a semi conductive material. Electronic devices can be made therefrom, including solar cells such as dye-sensitized solar cells.