Abstract: A printer fabricates an object from a computerized model using a fused filament fabrication process. The shape of an extrusion nozzle may be varied during extrusion to control, e.g., an amount of build material deposited, a shape of extrudate exiting the nozzle, a feature resolution, and the like.

Abstract: A system for separating objects within a stacked powder print bed of nested objects comprises a build box configured to contain the powder print bed. The build box has a build box top and a build box floor. The system further includes an elongated aperture formed in a side wall of the build box, and a de-powdering subsystem configured to mechanically and electrically engage the build box. A separating blade associated with the de-powdering subsystem is configured to be inserted through the elongated aperture and into the powder print bed between a top-most print bed layer of the nested objects and a second print bed layer directly below and contiguous with the top-most layer, thereby forming an isolated powder print bed between the separating blade and the build box top. The unbound powder may be agitated by various techniques and subsequently removed from the objects.

Abstract: A build box associated with a powder bed fabrication system may comprise a housing defining a housing cavity, and a powder print bed disposed within the housing cavity. The powder print bed may be characterized by state information. The build box may further comprise a medium configured to facilitate access to the state information, and a coupling interface for removably engaging the build box with at least one subsystem of the powder bed fabrication system. The state information may comprise one or more state information elements of object identification, object location, current processing state, next subsystem processing step, previous subsystem processing step, object model information, object material composition, and current powder print bed temperature profile. The medium may comprise a memory device coupled with a transceiver. The medium may alternatively comprise an RFID device, or an optically perceivable designator, such as a bar code or QR code.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer may be fabricated between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. Interface layers suitable for manufacture with an additive manufacturing system may resist the formation of bonds between a support structure and an object during subsequent sintering processes.

Abstract: Techniques and compositions are disclosed for feedstocks with powder/binder systems for three-dimensional printing, such as fused filament fabrication. For example, a feedstock may include a first high polymer and a second polymer for supporting a shape of a three-dimensional object through various processing stages. The first polymer may be a moderate or high molecular weight polymer, and the second polymer may be a high molecular weight polymer. The first polymer may provide improved print quality and strength, as compared to a low molecular weight polymer, in initial processing. In a solvent, the first polymer may be preferentially dissolved over the second polymer such that the second polymer may remain to support a net shape of the three-dimensional object in subsequent processing. Accordingly, the combination of the first polymer and the second polymer may be useful for rapid three-dimensional manufacturing of high quality parts.

Abstract: Techniques and compositions are disclosed for composite feedstocks with powder/binder systems suitable for three-dimensional printing, such as fused filament fabrication. The composite feedstocks may include a jacket about a core, with at least the core including a powder material suspended in a binder system and the jacket having a hardness or toughness greater than a hardness or toughness of the core for the feedstock. In general, the harder jacket may protect the core from unintended deformation or damage during transportation, storage, or use. For example, the difference in hardness or toughness between the jacket and the core may facilitate gripping the feedstock (e.g., by gear drives or the like) with a higher amount of force than is otherwise applicable if the feedstock were composed of the core alone, without damaging the core, during a fused filament fabrication process or another additive manufacturing process.

Abstract: A variety of additive manufacturing techniques can be adapted to fabricate a substantially net shape object from a computerized model using materials that can be debound and sintered into a fully dense metallic part or the like. However, during sintering, the net shape will shrink as binder escapes and the base material fuses into a dense final part. If the foundation beneath the object does not shrink in a corresponding fashion, the resulting stresses throughout the object can lead to fracturing, warping or other physical damage to the object resulting in a failed fabrication. To address this issue, a variety of techniques are disclosed for substrates and build plates that contract in a manner complementary to the object during debinding and sintering.

Abstract: Systems, methods, and components are disclosed for controlling layer separation in stereolithographic fabrication of three-dimensional objects. Each layer of the three-dimensional object can be cured and separated in discrete portions to facilitate controlling forces in the layers of a three-dimensional object. For example, controlling curing and separation of layers of a three-dimensional object according to the systems, methods, and components disclosed can facilitate accurately forming the three-dimensional object from cured particle-loaded resins. More specifically, particle loading can decrease the shear strength of the cured resin and, thus, controlling the forces exerted on a given layer of a cured particle-loaded resin can be particularly useful for reducing the likelihood of deformation in a three-dimensional object including the particles. In turn, the accurately formed three-dimensional object including the particles can be densified to form a dimensionally accurate finished part.

Abstract: Systems, methods, components, and materials are disclosed for stereolithographic fabrication of three-dimensional, dense objects. A resin including a first binder, a second binder, and dispersed particles can be exposed an activation light source to cure at least one of the binders in a layer-by-layer process to form a green object including the first binder, the second binder, and the particles. A dense object, such as a metal object, a ceramic object, or a combination thereof, can be formed from the green object by thermally processing the particles and removing the first binder through a primary debinding process, removing the second binder through a secondary debinding process different from the primary debinding process.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, a printer is configured to further fabricate an interface layer between the object and the support structure in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, a printer is configured to further fabricate an interface layer between the object and the support structure in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is fabricated between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering.

Abstract: Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.

Abstract: Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.

Abstract: Binder jetting techniques can be used to deposit and bind metallic particles or the like in a net shape for debinding and sintering into a final part. Where support structures are required to mitigate deformation of the object during the debinding and/or sintering, an interface layer may be formed between the support structures and portions of the object in order to avoid bonding of the support structure to the object during sintering.

Abstract: A powder bed is filled layer by layer with a sinterable powder and a liquid binder. After the liquid binder is applied, the liquid binder can be activated, e.g., by selectively curing cross-sections of the binder according to a computerized three-dimensional model of an object. In this manner, a sinterable net shape object can be formed within the powder bed layer by layer. The sinterable net shape can then be removed, debound as appropriate, and sintered into a final part.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. The support structure may be a multi-part support structure to mitigate mold lock or facilitate removal from enclosed spaces.

Abstract: A variety of additive manufacturing techniques can be adapted to fabricate a substantially net shape object from a computerized model using materials that can be debound and sintered into a fully dense metallic part or the like. However, during sintering, the net shape will shrink as binder escapes and the base material fuses into a dense final part. If the foundation beneath the object does not shrink in a corresponding fashion, the resulting stresses throughout the object can lead to fracturing, warping or other physical damage to the object resulting in a failed fabrication. To address this issue, a variety of techniques are disclosed for substrates and build plates that contract in a manner complementary to the object during debinding and sintering.

Abstract: A powder bed is filled layer by layer with a powdered build material containing an activatable binder. The binder in each new layer is locally activated according to a computerized three-dimensional model of an object to fabricate, layer by layer, a sinterable net shape of the object within the powder bed. The sinterable net shape can then be removed, debound as appropriate, and sintered into a final part.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering.