Abstract: A probe for an additive manufacturing system includes a probe body having a first air port therethrough between an inlet and an outlet, and a location sensing probe extending from the probe body. The location sensing probe includes a probe end and a probe bar, the probe bar coupled between the probe body and the probe end, and a channel surrounding the probe bar, the channel having an inner tube having an inlet proximate the probe body and an outlet proximate the probe end. A method of determining a position of an item being printed in an additive manufacturing system, includes probing the position with a location sensing probe having a resolution finer than a print resolution of the print head.

Abstract: An additive manufacturing system includes an extruder that includes a drive mechanism, a nozzle, and a pressure sensor. The drive mechanism is configured to feed a molten consumable material. The nozzle is attached at a distal end of the extruder and includes a nozzle tip, through which the molten consumable material is discharged as an extrudate. A pressure interface is fluidically coupled to an interior cavity of the nozzle. The pressure sensor is configured to operably measure a pressure within the interior cavity of the nozzle through the pressure interface.

Abstract: An additive manufacturing system includes an extruder having a motor and a pressure sensor. A filter receives speed values for the motor and generates a predicted pressure value from the speed values. A response threshold module sets a response threshold pressure value based on the predicted pressure value such that when the response threshold pressure value is between a pressure value from the pressure sensor and the predicted pressure value, a response is executed.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system, the method comprising generating and printing a planarizing part having a substantially-planar top surface relative to a build plane, and a bottom surface that substantially mirrors a topography of a platen surface, and printing the three-dimensional part over the substantially-planar top surface of the printed planarizing part.

Abstract: A starter piece for printing a three-dimensional item includes a main body having a face surface, a keel coupled to the main body, a guide tab extending from the keel, and at least one retaining mechanism coupled to the main body. Printing a three-dimensional item with an additive manufacturing system having a print foundation, a print head configured to print the three-dimensional item, and a plurality of support rails includes printing a support structure for the three-dimensional item in a layer by layer manner along the printing axis along with the printing of the three-dimensional item. The support structure is printed to provide a support between the three-dimensional item and the plurality of support rails of the additive manufacturing system.

Abstract: Method for printing a three-dimensional part layerwise with an additive manufacturing system includes printing layers by depositing material from a print head onto a print foundation, incrementing a position of the print head relative to the print foundation after each layer is printed, and indexing the print foundation carrying the printed layers away from the print head along the printing axis after a number of layers are printed. Printing is performed with driven and fixed rails clamped against movement of the print foundation. Moving the print foundation includes moving the driven rails with respect to the fixed rails in a direction substantially perpendicular to the build plane. Additive manufacturing system includes a drive mechanism to index the print foundation on the printing axis using fixed and driven rails, the driven rails engaging the print foundation for moving the print foundation.

Abstract: An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.

Abstract: A probe for an additive manufacturing system includes a probe body having a first air port therethrough between an inlet and an outlet, and a location sensing probe extending from the probe body. The location sensing probe includes a probe end and a probe bar, the probe bar coupled between the probe body and the probe end, and a channel surrounding the probe bar, the channel having an inner tube having an inlet proximate the probe body and an outlet proximate the probe end. A method of determining a position of an item being printed in an additive manufacturing system, includes probing the position with a location sensing probe having a resolution finer than a print resolution of the print head.

Abstract: A probe for an additive manufacturing system includes a probe body having a first air port therethrough between an inlet and an outlet, and a location sensing probe extending from the probe body. The location sensing probe includes a probe end and a probe bar, the probe bar coupled between the probe body and the probe end, and a channel surrounding the probe bar, the channel having an inner tube having an inlet proximate the probe body and an outlet proximate the probe end. A method of determining a position of an item being printed in an additive manufacturing system, includes probing the position with a location sensing probe having a resolution finer than a print resolution of the print head.

Abstract: An additive manufacturing system includes an extruder that includes a drive mechanism, a nozzle, and a pressure sensor. The drive mechanism is configured to feed a molten consumable material. The nozzle is attached at a distal end of the extruder and includes a nozzle tip, through which the molten consumable material is discharged as an extrudate. A pressure interface is fluidically coupled to an interior cavity of the nozzle. The pressure sensor is configured to operably measure a pressure within the interior cavity of the nozzle through the pressure interface.

Abstract: An additive manufacturing system includes an extruder having a motor and a pressure sensor. A filter receives speed values for the motor and generates a predicted pressure value from the speed values. A response threshold module sets a response threshold pressure value based on the predicted pressure value such that when the response threshold pressure value is between a pressure value from the pressure sensor and the predicted pressure value, a response is executed.

Abstract: An additive manufacturing system for printing three-dimensional parts, the system including a build chamber having an opening with first and second opposing edges, and a platen in the build chamber. A baffle door expandable across the opening has a first baffle section attached at the first opposing edge and configured to extend between a first position adjacent the first opposing edge and a second position adjacent the second opposing edge, a second baffle section attached at the second opposing edge and configured to extend between a first position adjacent the second opposing edge and a second position adjacent the first opposing edge, and a third baffle section having a frame, a tool port in the frame, and baffles on either side of the tool port, the baffles configured to expand and contract in a second direction substantially perpendicular to the first direction as the tool port moves within the frame. The baffle door insulates the build chamber.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system, the method comprising generating and printing a planarizing part having a substantially-planar top surface relative to a build plane, and a bottom surface that substantially mirrors a topography of a platen surface, and printing the three-dimensional part over the substantially-planar top surface of the printed planarizing part.

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 method for printing a three-dimensional part with an additive manufacturing system, the method comprising generating and printing a planarizing part having a substantially-planar top surface relative to a build plane, and a bottom surface that substantially mirrors a topography of a platen surface, and printing the three-dimensional part over the substantially-planar top surface of the printed planarizing part.

Abstract: An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.

Abstract: An additive manufacturing system for printing three-dimensional parts, the system including a print head configured to print a part material along a non-vertical printing axis, a non-horizontal print foundation configured to receive the printed part material from the print head to produce the three-dimensional part in a layer-by-layer manner, a drive mechanism configured to index the print foundation along the non-vertical printing axis, and a controller operably coupled to control the print head and the drive mechanism. The controller is configured to cause the print head to print the part according to a method of printing including printing a support structure below the part on the non-horizontal print foundation, wherein the part and the support structure are physically separated, and wherein the support structure is configured to support the part during printing as the part is elongated.