Abstract: A low pull force system for feeding a filament along a feed path from a source to a liquefier in a 3D printer includes a low compressive force loading drive for advancing filament from the source, a feed drive for advancing filament into the liquefier, and an in-line accumulator comprising a telescoping joint positioned in the feed path between the loading drive and the feed drive. When the telescoping joint is in a contracted position, the loading drive activates to feed filament into the feed path at a rate faster than a rate at which the feed drive advances filament into the liquefier, causing the telescoping joint to expand and accrue a slack of filament in the feed path. When the telescoping joint reaches an extended position, the loading drive deactivates while the feed drive continues to advance filament into the liquefier, and the slack of filament is consumed.

Abstract: A low pull force system for feeding a filament along a feed path from a source to a liquefier in a 3D printer includes a low compressive force loading drive for advancing filament from the source, a feed drive for advancing filament into the liquefier, and an in-line accumulator comprising a telescoping joint positioned in the feed path between the loading drive and the feed drive. When the telescoping joint is in a contracted position, the loading drive activates to feed filament into the feed path at a rate faster than a rate at which the feed drive advances filament into the liquefier, causing the telescoping joint to expand and accrue a slack of filament in the feed path. When the telescoping joint reaches an extended position, the loading drive deactivates while the feed drive continues to advance filament into the liquefier, and the slack of filament is consumed.

Abstract: A low pull force system for feeding a filament along a feed path from a source to a liquefier in a 3D printer includes a low compressive force loading drive for advancing filament from the source, a feed drive for advancing filament into the liquefier, and an in-line accumulator comprising a telescoping joint positioned in the feed path between the loading drive and the feed drive. When the telescoping joint is in a contracted position, the loading drive activates to feed filament into the feed path at a rate faster than a rate at which the feed drive advances filament into the liquefier, causing the telescoping joint to expand and accrue a slack of filament in the feed path. When the telescoping joint reaches an extended position, the loading drive deactivates while the feed drive continues to advance filament into the liquefier, and the slack of filament is consumed.

Abstract: A low compressive force filament drive system for use with an additive manufacturing system includes a plurality of drives spaced from each other. Each drive includes a first rotatable shaft and a second rotatable shaft engaged with the first rotatable shaft in a counter rotational configuration. The filament drive system includes a pair of drive wheel, each fixedly attached to a shaft and comprising a groove about a circumference having a substantially smooth surface and positioned on opposing sides of a filament path with a gap therebetween so as to frictionally engage a filament provided in the filament path. The drive includes one or more bridge shafts, wherein each bridge shaft is configured to rotatably couple the adjacent drives of the plurality of drives, wherein the shafts are configured to be directly or indirectly driven by a motor.

Abstract: An apparatus and a method using the apparatus provides heated air in an additive manufacturing process for building a three-dimensional part. The method comprises providing a stream of flowable part material at an initial build level, the initial build level being positioned in and defining a horizontal plane wherein the stream of flowable material is being initially disposed on previously deposited part material. Heated air is provided at a selected temperature corresponding to the temperature of the stream of flowable part material such that the stream of flowable part material deposits on previously deposited part material in an adhering fashion thereby forming the three-dimensional part wherein the heated air is provided in the horizontal plane of the initial build level.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system includes a liquefier tube compositionally comprising a metallic material, and having a first end and a second end offset along a longitudinal axis, and a flow channel extending from the first end to the second end. The assembly further includes an extrusion tip compositionally comprising a metallic material and coupled to the second end of the liquefier tube, the extrusion tip having a cavity having an interior shoulder wherein the cavity terminates in an opening. The liquefier includes a hardened insert compositionally comprising a material that is harder than the metallic material of the extrusion tip and the metallic material of the liquefier tube. The hardened insert has an exterior shoulder that engages the interior shoulder of the extrusion tip such that the insert is press fit within the extrusion tip.

Abstract: A low pull force system for feeding a filament along a feed path from a source to a liquefier in a 3D printer includes a low compressive force loading drive for advancing filament from the source, a feed drive for advancing filament into the liquefier, and an in-line accumulator comprising a telescoping joint positioned in the feed path between the loading drive and the feed drive. When the telescoping joint is in a contracted position, the loading drive activates to feed filament into the feed path at a rate faster than a rate at which the feed drive advances filament into the liquefier, causing the telescoping joint to expand and accrue a slack of filament in the feed path. When the telescoping joint reaches an extended position, the loading drive deactivates while the feed drive continues to advance filament into the liquefier, and the slack of filament is consumed.

Abstract: A low compressive force filament drive system for use with an additive manufacturing system includes a plurality of drives spaced from each other. Each drive includes a first rotatable shaft and a second rotatable shaft engaged with the first rotatable shaft in a counter rotational configuration. The filament drive system includes a pair of drive wheel, each fixedly attached to a shaft and comprising a groove about a circumference having a substantially smooth surface and positioned on opposing sides of a filament path with a gap therebetween so as to frictionally engage a filament provided in the filament path. The drive includes one or more bridge shafts, wherein each bridge shaft is configured to rotatably couple the adjacent drives of the plurality of drives, wherein the shafts are configured to be directly or indirectly driven by a motor.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system includes a liquefier tube compositionally comprising a metallic material, and having a first end and a second end offset along a longitudinal axis, and a flow channel extending from the first end to the second end. The assembly further includes an extrusion tip compositionally comprising a metallic material and coupled to the second end of the liquefier tube, the extrusion tip having a cavity having an interior shoulder wherein the cavity terminates in an opening. The liquefier includes a hardened insert compositionally comprising a material that is harder than the metallic material of the extrusion tip and the metallic material of the liquefier tube. The hardened insert has an exterior shoulder that engages the interior shoulder of the extrusion tip such that the insert is press fit within the extrusion tip.

Abstract: A platen assembly for use in a 3D printer includes a frame and a platen supported by the frame. The platen is configured to receive a removable build tray. A lever release mechanism of the platen assembly is coupled to the frame and is configured to both secure the build tray to the platen for printing of the part, and to eject the build tray from the platen after printing of the part.

Abstract: An 3D printer has a gantry configured to move in a plane substantially parallel to a build plane. The system includes a platen configured to support a part being built in a layer by layer process, wherein the platen is configured to move in a direction substantially normal to the build plane. The system includes a head carriage carried by the gantry wherein the head carriage includes a first support member supporting a retaining mechanism. The retaining mechanism includes at least one member extending from the support member and a camming member rotatably attached to the support member and movable about an axis of rotation. The camming member has arcuate camming surface with an increasing radial distance from the axis of rotation. The system includes at least one print head having a housing with a first side surface configured to engage the at least one member and a second side surface configured to engage the arcuate camming surface.

Abstract: A 3D printer includes at least one consumable loading bay configured to supply filament from a consumable supply assembly to a print head and at least one drive assembly that is configured to advance filament to the print head from the consumable supply. Each drive assembly includes a follower wheel rotatable about a follower axis and a drive wheel spaced apart from the follower wheel. The drive wheel is rotatable about a drive axis and is located on an opposing side of a filament path from the follower wheel such that the follower axis and the drive axis are substantially parallel. The drive wheel further includes an outer surface extending between two ends and has at least one engaging portion that is configured to engage with the filament and at least one disengaging portion that is configured to disengage from the filament.

Abstract: A 3D printer has a gantry configured to move in a plane substantially parallel to a build plane, and a platen configured to support a part being built. The platen is configured to move in a direction substantially normal to the build plane. A head carriage is carried by the gantry, and a print head is carried by and retained in the head carriage. A material container has a material container body and a material container cover configured to allow loading of a spool containing a supply of a consumable filament for printing with the 3D printer, the spool mounted on an axle containing a spool chip and electrical contacts. The material container body includes a first and second axle channels configured to accept first and second ends of the axle. The first axle channel has a number of electrical contacts and is tapered to orient the axle to align the axle contacts with the first axle channel contacts.

Abstract: An apparatus and a method using the apparatus provides heated air in an additive manufacturing process for building a three-dimensional part. The method comprises providing a stream of flowable part material at an initial build level, the initial build level being positioned in and defining a horizontal plane wherein the stream of flowable material is being initially disposed on previously deposited part material. Heated air is provided at a selected temperature corresponding to the temperature of the stream of flowable part material such that the stream of flowable part material deposits on previously deposited part material in an adhering fashion thereby forming the three-dimensional part where in the heated air is provided in the horizontal plane of the initial build level.

Abstract: An apparatus and a method using the apparatus provides heated air in an additive manufacturing process for building a three-dimensional part. The method comprises providing a stream of flowable part material at an initial build level, the initial build level being positioned in and defining a horizontal plane wherein the stream of flowable material is being initially disposed on previously deposited part material. Heated air is provided at a selected temperature corresponding to the temperature of the stream of flowable part material such that the stream of flowable part material deposits on previously deposited part material in an adhering fashion thereby forming the three-dimensional part wherein the heated air is provided in the horizontal plane of the initial build level.

Abstract: A 3D printer has a gantry configured to move in a plane substantially parallel to a build plane, and a platen configured to support a part being built. The platen is configured to move in a direction substantially normal to the build plane. A head carriage is carried by the gantry, and a print head is carried by and retained in the head carriage. A material container has a material container body and a material container cover configured to allow loading of a spool containing a supply of a consumable filament for printing with the 3D printer, the spool mounted on an axle containing a spool chip and electrical contacts. The material container body includes a first and second axle channels configured to accept first and second ends of the axle. The first axle channel has a number of electrical contacts and is tapered to orient the axle to align the axle contacts with the first axle channel contacts.

Abstract: An apparatus and a method using the apparatus provides heated air in an additive manufacturing process for building a three-dimensional part. The method comprises providing a stream of flowable part material at an initial build level, the initial build level being positioned in and defining a horizontal plane wherein the stream of flowable material is being initially disposed on previously deposited part material. Heated air is provided at a selected temperature corresponding to the temperature of the stream of flowable part material such that the stream of flowable part material deposits on previously deposited part material in an adhering fashion thereby forming the three-dimensional part where in the heated air is provided in the horizontal plane of the initial build level.

Abstract: A 3D printer includes at least one consumable loading bay configured to supply filament from a consumable supply assembly to a print head and at least one drive assembly that is configured to advance filament to the print head from the consumable supply. Each drive assembly includes a follower wheel rotatable about a follower axis and a drive wheel spaced apart from the follower wheel. The drive wheel is rotatable about a drive axis and is located on an opposing side of a filament path from the follower wheel such that the follower axis and the drive axis are substantially parallel. The drive wheel further includes an outer surface extending between two ends and has at least one engaging portion that is configured to engage with the filament and at least one disengaging portion that is configured to disengage from the filament.

Abstract: An 3D printer has a gantry configured to move in a plane substantially parallel to a build plane. The system includes a platen configured to support a part being built in a layer by layer process, wherein the platen is configured to move in a direction substantially normal to the build plane. The system includes a head carriage carried by the gantry wherein the head carriage includes a first support member supporting a retaining mechanism. The retaining mechanism includes at least one member extending from the support member and a camming member rotatably attached to the support member and movable about an axis of rotation. The camming member has arcuate camming surface with an increasing radial distance from the axis of rotation. The system includes at least one print head having a housing with a first side surface configured to engage the at least one member and a second side surface configured to engage the arcuate camming surface.