Abstract: An additive manufacturing guide for variable size additive manufacturing is provided. The additive manufacturing guide includes an actuator movable between a maximum flow position and a minimum flow position. The additive manufacturing guide also includes an adjustable port defining a variable area outlet aperture. The actuator is configured to deform the adjustable port to selectively resize the variable area outlet aperture. The maximum flow position corresponds to a maximum area of the variable area outlet aperture and the minimum flow position corresponds to a minimum area of the variable area outlet aperture. An additive manufacturing system including the additive manufacturing guide is also provided. A method of additive manufacturing with variable bead sizes using the additive manufacturing guide is further provided.

Abstract: A static mixer is disclosed. The static mixer comprises a housing (22) defining an internal mixing cavity (36) that longitudinally extends along a central axis between an inlet (38) and an outlet (40) and is adapted for axial flow of a fluid therethrough. The static mixer also comprises a mixing element (42) disposed within the mixing cavity (36). The mixing element (42) is configured to be free from an impingement surface oriented substantially perpendicular to a main direction of fluid flow through the internal mixing cavity (36). The mixing element (42) comprises an elongated mixing blade that is oriented longitudinally within the mixing cavity (36) and comprises a nose axially oriented toward the inlet (38). The static mixer may comprise a heat-exchanging jacket integrally formed with the housing (22). An additive manufacturing system comprising the static mixer, and methods of making and using the same, are also disclosed.

Abstract: A method of forming a three-dimensional (3D) pattern or article comprises: (1) selecting a first composition to be printed with a nozzle of an apparatus; (II) identifying desired characteristics of a pattern or layer (“pattern/layer”) to be formed by printing the first composition; (Ill) determining dimensional differences between the desired characteristics of the pattern/layer and predicted characteristics of the pattern/layer based on computational simulation modeling, or determining dimensional differences between the desired characteristics of the pattern/layer and actual characteristics of a trial layer, based on a flow rate of the first composition, a speed of a substrate and/or the nozzle, and the desired characteristics of the pattern/layer; and (IV) printing the first composition with the nozzle on the substrate to form the pattern/layer. The method comprises, during (IV) printing, (V) implementing a correction signal to adjust a flow rate of the first composition.

Abstract: A static mixer is disclosed. The static mixer comprises a housing (22) defining an internal mixing cavity (36) that longitudinally extends along a central axis between an inlet (38) and an outlet (40) and is adapted for axial flow of a fluid therethrough. The static mixer also comprises a mixing element (42) disposed within the mixing cavity (36). The mixing element (42) is configured to be free from an impingement surface oriented substantially perpendicular to a main direction of fluid flow through the internal mixing cavity (36). The mixing element (42) comprises an elongated mixing blade that is oriented longitudinally within the mixing cavity (36) and comprises a nose axially oriented toward the inlet (38). The static mixer may comprise a heat-exchanging jacket integrally formed with the housing (22). An additive manufacturing system comprising the static mixer, and methods of making and using the same, are also disclosed.