Abstract: A consumable cartridge for a plasma arc torch includes a cartridge frame having a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, the second end including a plurality of discrete retaining features. The consumable cartridge includes an electrically conductive contact element secured to the cartridge frame by the plurality of discrete retaining features and translatable up to a predetermined distance within the cartridge frame along the longitudinal axis at the second end, the contact element having a core, a proximal surface, and a distal surface. The proximal surface is shaped to contact a torch plunger of the plasma arc torch upon installation into the plasma arc torch and the distal surface is shaped to contact an electrode of the plasma arc torch during an operation of the plasma arc torch.

Abstract: A translatable electrode for use in a cartridge assembly for a contact start plasma arc torch including an electrode body having a longitudinal axis and including a proximal end and a distal end. The proximal end including a spiral groove and a contact surface at a proximal end face shaped to electrically communicate with a cathodic element. The translatable electrode also including at least one emissive insert disposed within the distal end of the electrode body and proximate a distal end face. The translatable electrode including at least one baffle disposed between the proximal and distal end of the electrode body. The translatable electrode also including a gas flow dampening region disposed circumferentially about the distal end and adjacent the distal end face and positioned between the at least one baffle and the distal end face.

Abstract: A nozzle for a gas-cooled plasma arc torch is provided. The nozzle includes a nozzle body formed from a first metal. The nozzle body comprises a proximal portion and a distal portion extending along a longitudinal axis. The distal portion of the nozzle body comprises a first bore. The nozzle also includes an arc transition component formed from a second metal. The arc transition component is coupled to the distal portion of the nozzle body and comprises a second bore configured to substantially align with the first bore when the arc transition component is coupled to the nozzle body. The second metal of the arc transition component comprises a noble metal and the second metal is different from the first metal.

Abstract: A computer-implemented method is provided for shaping an edge of a part to be cut from a workpiece using a material processing system comprising a processing head configured to deliver a processing stream. The method includes calculating a start point and an end point of a shaping path proximate to the edge of the part based on a desired edge profile and determining a set of operating parameters to controllably impinge the processing stream about the edge of the part to execute the shaping path from the start point to the end point. The method further includes positioning the processing head normal to a surface of the part and controllably impinging the processing stream at the edge of the part, by the processing head, to shape the desired edge profile.

Abstract: A translatable electrode for use in a cartridge assembly for a contact start plasma arc torch including an electrode body having a longitudinal axis and including a proximal end and a distal end. The proximal end including a spiral groove and a contact surface at a proximal end face shaped to electrically communicate with a cathodic element. The translatable electrode also including at least one emissive insert disposed within the distal end of the electrode body and proximate a distal end face. The translatable electrode including at least one baffle disposed between the proximal and distal end of the electrode body. The translatable electrode also including a gas flow dampening region disposed circumferentially about the distal end and adjacent the distal end face and positioned between the at least one baffle and the distal end face.

Abstract: A consumable cartridge for a plasma arc torch includes a cartridge frame having a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, the second end including a plurality of discrete retaining features. The consumable cartridge includes an electrically conductive contact element secured to the cartridge frame by the plurality of discrete retaining features and translatable up to a predetermined distance within the cartridge frame along the longitudinal axis at the second end, the contact element having a core, a proximal surface, and a distal surface. The proximal surface is shaped to contact a torch plunger of the plasma arc torch upon installation into the plasma arc torch and the distal surface is shaped to contact an electrode of the plasma arc torch during an operation of the plasma arc torch.

Abstract: Described herein are three-dimensional (3D) printer systems and methods, which may provide for “continuous pull” 3D printing. An illustrative 3D printer includes: a resin container, a base plate, a light source arranged below the resin container and operable to cure resin in the resin container; and a control system operable to: (a) receive model data specifying a 3D structure; (b) determine 2D images corresponding to layers of the 3D object; and (c) generate control signals to operate the light source and the base plate to sequentially form the layers of the 3D object onto the base plate, wherein the base plate moves a formed portion of the 3D object upward after formation of each layer, and wherein at least a surface of a formed portion of the 3D object remains in contact with the resin in the resin container throughout the formation of the layers of the 3D object.

Abstract: A consumable cartridge for a plasma arc torch includes a cartridge frame having a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, the second end including a plurality of discrete retaining features. The consumable cartridge includes an electrically conductive contact element secured to the cartridge frame by the plurality of discrete retaining features and translatable up to a predetermined distance within the cartridge frame along the longitudinal axis at the second end, the contact element having a core, a proximal surface, and a distal surface. The proximal surface is shaped to contact a torch plunger of the plasma arc torch upon installation into the plasma arc torch and the distal surface is shaped to contact an electrode of the plasma arc torch during an operation of the plasma arc torch.

Abstract: Described herein are three-dimensional (3D) printer systems and methods, which may provide for “continuous pull” 3D printing. An illustrative 3D printer includes: a resin container, a base plate, a light source arranged below the resin container and operable to cure resin in the resin container; and a control system operable to: (a) receive model data specifying a 3D structure; (b) determine 2D images corresponding to layers of the 3D object; and (c) generate control signals to operate the light source and the base plate to sequentially form the layers of the 3D object onto the base plate, wherein the base plate moves a formed portion of the 3D object upward after formation of each layer, and wherein at least a surface of a formed portion of the 3D object remains in contact with the resin in the resin container throughout the formation of the layers of the 3D object.

Abstract: Described herein are three-dimensional (3D) printer systems and methods, which may provide for “continuous pull” 3D printing. An illustrative 3D printer includes: a resin container, a base plate, a light source arranged below the resin container and operable to cure resin in the resin container; and a control system operable to: (a) receive model data specifying a 3D structure; (b) determine 2D images corresponding to layers of the 3D object; and (c) generate control signals to operate the light source and the base plate to sequentially form the layers of the 3D object onto the base plate, wherein the base plate moves a formed portion of the 3D object upward after formation of each layer, and wherein at least a surface of a formed portion of the 3D object remains in contact with the resin in the resin container throughout the formation of the layers of the 3D object.

Abstract: A swirl ring for a plasma arc torch includes a body configured to at least partially surround and slidingly engage an electrode of the plasma arc torch. The body includes a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, and at least one protuberance extending from the second end in a direction of the longitudinal axis. The at least one protuberance is configured to engage a switch of the plasma arc torch for sensing a presence of a swirl ring in the plasma arc torch.

Abstract: A torch tip assembly of a plasma arc torch is provided for delivering a diffused stream of plasma arc in a gouging operation. The assembly comprises a nozzle including a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end. A nozzle exit orifice of the nozzle body defines at least a bore for conducting the plasma arc therethrough. The assembly also comprises a counter bore feature, disposed relative to the distal end the nozzle body, fluidly connected to the bore and located distally relative to the bore. At least one of the bore or the counter bore feature has a non-circular cross-sectional shape in a plane perpendicular to the longitudinal axis. The non-circular cross-sectional shape is configured to enable a second non-circular cross-sectional shape in the plasma arc that diffuses the plasma arc.

Abstract: A swirl ring for a plasma arc torch includes a body configured to at least partially surround and slidingly engage an electrode of the plasma arc torch. The body includes a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, and at least one protuberance extending from the second end in a direction of the longitudinal axis. The at least one protuberance is configured to engage a switch of the plasma arc torch for sensing a presence of a swirl ring in the plasma arc torch.

Abstract: A consumable cartridge for a plasma arc torch includes a cartridge frame having a first end and a second end opposite the first end, the first and second ends defining a longitudinal axis, the second end including a plurality of discrete retaining features. The consumable cartridge includes an electrically conductive contact element secured to the cartridge frame by the plurality of discrete retaining features and translatable up to a predetermined distance within the cartridge frame along the longitudinal axis at the second end, the contact element having a core, a proximal surface, and a distal surface. The proximal surface is shaped to contact a torch plunger of the plasma arc torch upon installation into the plasma arc torch and the distal surface is shaped to contact an electrode of the plasma arc torch during an operation of the plasma arc torch.

Abstract: A torch tip assembly of a plasma arc torch is provided for delivering a diffused stream of plasma arc in a gouging operation. The assembly comprises a nozzle including a nozzle body defining a central longitudinal axis extending between a proximal end and a distal end. A nozzle exit orifice of the nozzle body defines at least a bore for conducting the plasma arc therethrough. The assembly also comprises a counter bore feature, disposed relative to the distal end the nozzle body, fluidly connected to the bore and located distally relative to the bore. At least one of the bore or the counter bore feature has a non-circular cross-sectional shape in a plane perpendicular to the longitudinal axis. The non-circular cross-sectional shape is configured to enable a second non-circular cross-sectional shape in the plasma arc that diffuses the plasma arc.

Abstract: Described herein are three-dimensional (3D) printer systems and methods, which may provide for “continuous pull” 3D printing. An illustrative 3D printer includes: a resin container, a base plate, a light source arranged below the resin container and operable to cure resin in the resin container; and a control system operable to: (a) receive model data specifying a 3D structure; (b) determine 2D images corresponding to layers of the 3D object; and (c) generate control signals to operate the light source and the base plate to sequentially form the layers of the 3D object onto the base plate, wherein the base plate moves a formed portion of the 3D object upward after formation of each layer, and wherein at least a surface of a formed portion of the 3D object remains in contact with the resin in the resin container throughout the formation of the layers of the 3D object.

Abstract: A torch tip for a plasma arc torch includes a body having a first end, configured to attach to the torch, and a second end, where an end wall is disposed. A plasma exit orifice is formed in the end wall. At least two castellations are formed in the end wall. Each castellation has a castellation width defined by the distance between the sidewalls of that castellation. At least one slot is disposed between two castellations. Each slot has a slot width defined by a distance between the sidewalls of its adjacent castellations. The slot width can be at least twice the castellation width. Each slot also has a slot floor and an exterior shape. The slot floor can have slope that tapers toward the first end of the body in an outward radial direction and the exterior shape of the slot can have a generally V-shaped or U-shaped contour.

Abstract: A torch tip for a plasma arc torch includes a body having a first end, configured to attach to the torch, and a second end, where an end wall is disposed. A plasma exit orifice is formed in the end wall. At least two castellations are formed in the end wall. Each castellation has a castellation width defined by the distance between the sidewalls of that castellation. At least one slot is disposed between two castellations. Each slot has a slot width defined by a distance between the sidewalls of its adjacent castellations. The slot width can be at least twice the castellation width. Each slot also has a slot floor and an exterior shape. The slot floor can have slope that tapers toward the first end of the body in an outward radial direction and the exterior shape of the slot can have a generally V-shaped or U-shaped contour.