Abstract: A method for identifying an angular deviation in the orientation of a multi-nozzle extruder includes moving the multi-nozzle extruder in a first process direction to form a first extrusion material swath and moving the multi-nozzle extruder in a second process direction opposing the first process direction to form a second extrusion material swath. The method further includes identifying widths and heights of the swaths from scanned image data and identifying a component of angular deviation for the multi-nozzle extruder with reference to at least one of a difference between the first swath width and the second swath width and another difference between the first swath height and the second swath height.

Abstract: An additive manufacturing system opens the valves in an extruder needed to form a swath and operates an actuator to move the extruder through a transition region with those valves open to establish an amount of extrusion material between a faceplate of the extruder and a portion of an object being formed that is adequate for formation of a swath. The length of the transition region is determined with reference to a viscosity of the material being extruded and a speed at which the extruder is moved to form the swath. The transition region can be perpendicular to a path of the extruder to form the swath or aligned with the path of the extruder to form the swath.

Abstract: An imaging blanket comprises a base comprising an elastic polymer and sulfur. A barrier layer is on the base and a surface layer is on the barrier layer. The surface layer comprises an elastomer and a platinum catalyst.

Abstract: A system, method and apparatus for in-situ cleaning comprises a shower configured to dispense cleaning solution on a belt in a rendering device a dryer configured down line from the shower; a cleaning roller configured to engage a transport roller associated with the belt and a control system for controlling operations thereof.

Abstract: A method of operating an additive manufacturing system feeds solid extrusion material into a heater using a slip clutch coupled to an actuator of a mechanical driver to supply thermoplastic material into a manifold in an extruder head. The method sets a speed of the actuator so the actuator operates at a rotational speed that is slightly greater than the rotational speed of the mechanical mover. This method helps maintain the pressure of the thermoplastic material in the manifold of the extruder head in a predetermined range no matter how many nozzles are opened in the extruder head.

Abstract: An additive manufacturing system has a plurality of manifolds in an extruder. Each manifold is connected to at least one nozzle of the extruder so the at least one nozzle extrudes thermoplastic material through a corresponding aperture in a faceplate mounted to the extruder. A plurality of valves is configured between each manifold and each nozzle connected to the manifold so the nozzles connected to a manifold extrude thermoplastic material from the manifold selectively. The faceplate is also configured for rotation about an axis perpendicular to the faceplate so different orientations of the nozzles and the apertures of the faceplate can be obtained. The different manifolds of the extruder enable a plurality of thermoplastic materials having different properties to be extruded simultaneously so the materials can join to one another while the materials are at an elevated temperature.

Abstract: An additive manufacturing system includes a slip clutch coupled to an actuator of a mechanical driver that feeds solid extrusion material into a heater for supplying thermoplastic material to a manifold in an extruder head. A speed of the actuator can be set to enable the actuator to operate at a rotational speed that is slightly greater than the rotational speed of the mechanical mover. This configuration enables the pressure of the thermoplastic material in the manifold of the extruder head to be in a predetermined range no matter how many nozzles are opened in the extruder head.

Abstract: A cooling system comprising of a coolant manifold, a heat sink configured to fit in the coolant manifold, a plurality of cooling fins formed in the heat sink, and a coolant configured to flow through the coolant manifold to the heat sink. Diamond shaped pin fins associated with the heat sink create a series of divergent fluid paths for the cooling fluid that helps to create turbulence and improved heat transfer.

Abstract: A multi-nozzle extrusion printhead includes a chamber with an inlet to receive an extrusion material and a plurality of outlets fluidly coupled to the chamber. The printhead also includes a plurality of valves that control flow of extrusion material through the fluid outlets to nozzles in the printhead. Each valve includes a member and an electromechanical actuator configured to move the member to a first position to block a flow of the extrusion material through one of the fluid outlets and nozzles and to a second position to enable the flow of the extrusion material through the fluid outlet and nozzles.

Abstract: A method of operating a multi-nozzle extruder in an additive manufacturing system enables support structure to be formed while an object is also being formed. The method includes opening more than one nozzle in the multi-nozzle extruder, and operating an actuator with a controller to move the multi-nozzle extruder along a path to form a first group of multiple parallel ribbons of support structure simultaneously with material extruded from the more than one open nozzle.

Abstract: An additive manufacturing system has a plurality of manifolds in an extruder. Each manifold is connected to at least one nozzle of the extruder to enable the at least one nozzle to extrude thermoplastic material through a corresponding aperture in a faceplate mounted to the extruder. A plurality of valves is configured between each manifold and each nozzle connected to the manifold to enable the nozzles connected to a manifold to extrude thermoplastic material from the manifold selectively. The faceplate is also configured for rotation about an axis perpendicular to the faceplate to enable different orientations of the nozzles in the apertures of the faceplate. The different manifolds of the extruder enable a plurality of thermoplastic materials having a different property to be extruded simultaneously so the materials can join to one another while the materials are at an elevated temperature.

Abstract: An extruder head has an arrangement of multiple nozzles in the faceplate that avoids aligning the multiple nozzles at angular orientations from the 0°-180° axis and 90°-270° axis intersection at the center of the faceplate. The extruder head includes a housing having a faceplate with a plurality of nozzles that are equally spaced from one another when the nozzles are projected onto a first axis in a plane of the faceplate and the nozzles are equally spaced from one another when projected onto a second axis in the plane of the faceplate that is orthogonal to the first axis. Movement of the extruder head along any angular path from the intersection of the first axis and the second axis in the plane of the faceplate enables at least one nozzle in the plurality of nozzles to not be aligned with any other nozzle.

Abstract: A method of operating an extruder assembly in a three-dimensional object printer translates and rotates an extruder body having an extrusion slot to produce three-dimensional objects more quickly and with greater precision. The method also includes rotating and moving one or more shutter bodies with respect to the extrusion slot to form a continuous filament of material of various sizes and shapes.

Abstract: A method for identifying an angular deviation in the orientation of a multi-nozzle extruder includes moving the multi-nozzle extruder in a first process direction to form a first extrusion material swath and moving the multi-nozzle extruder in a second process direction opposing the first process direction to form a second extrusion material swath. The method further includes identifying widths and heights of the swaths from scanned image data and identifying a component of angular deviation for the multi-nozzle extruder with reference to at least one of a difference between the first swath width and the second swath width and another difference between the first swath height and the second swath height.

Abstract: An extruder has a valve assembly configured to move pins to open and close the nozzles in a multi-nozzle extruder head independently. The pins of the valve assembly that are driven by actuators into and out of engagement with nozzles in the extruder head are positioned within sleeves that extend between the valve assembly and the extruder head. A gap is provided between the extruder head and the end of the sleeves proximate the extruder head to enable thermoplastic material leaking from the extruder that contacts the pins to remain in a melted or plastic state so the thermoplastic material does not interfere with the movement of the pins.

Abstract: An extruder assembly for a three-dimensional object has an extrusion slot to enable faster three-dimensional object printing with greater precision. The extruder assembly includes an extruder body having an extrusion slot to enable a continuous filament of material to be extruded through the extrusion slot and at least one actuator operatively connected to the extruder body. The at least one actuator is configured to translate the extruder body in a horizontal plane and rotate the extruder body about a rotational axis.

Abstract: A method for identifying an angle of roll for a multi-nozzle extruder includes moving the extruder in a first process direction to form a first set of swaths of extrusion material using two nozzles in the extruder and moving the extruder in a second process direction to form a second set of swaths of extrusion material. The method further includes identifying a location of one nozzle relative to the other nozzle in two dimensions based on cross-process direction distances between the first and second sets of swaths and identifying the angle of extruder roll for the extruder based on the location of the one nozzle and a predetermined geometry of the extruder.

Abstract: An apparatus changes the temperature of thermoplastic material in an extruder head to reduce the time for producing an object. The apparatus includes a cooling device located near the one or more nozzles of the extruder head to change the temperature of the thermoplastic material extruded by the extruder head. The apparatus cools the thermoplastic material to enhance the formation of exterior object features. A heater can also be positioned near the nozzle zone to heat the thermoplastic material to reduce the time for raising the viscosity of the thermoplastic material for forming interior regions of the object.

Abstract: A method for identifying an angular deviation in the orientation of a multi-nozzle extruder includes moving the multi-nozzle extruder in a first process direction to form a first extrusion material swath and moving the multi-nozzle extruder in a second process direction opposing the first process direction to form a second extrusion material swath. The method further includes identifying widths and heights of the swaths from scanned image data and identifying a component of angular deviation for the multi-nozzle extruder with reference to at least one of a difference between the first swath width and the second swath width and another difference between the first swath height and the second swath height.

Abstract: An additive manufacturing system operates at least one ejector and an extruder to form three-dimensional objects with photopolymer material and thermoplastic material. The system operates to deposit the two materials in a layer-by-layer manner. The photopolymer material provides high resolution finishes on the objects and the thermoplastic material enables strong and stable formation of internal portions of the objects.