Abstract: A consumable assembly for supplying filament to a 3D printer includes a spool-less filament coil, a payout tube, and a compressive band. The coil of filament is wound in a configuration having a generally cylindrical outer perimeter and an open interior; the coil has a payout hole extending from an inner layer of the coil to an outer layer of the coil and includes a filament strand configured to be withdrawn through the payout hole in response to a pull force, to thereby withdraw filament from the interior of the coil. The payout tube is disposed in the payout hole and provides a filament port. A compressive band is disposed over the outer layer and is configured to exert a compressive radial force on the coil so that the coil maintains its cylindrical shape without deformation, and the filament strand may be drawn through the filament outlet free of kinks, twists or tangles.

Abstract: A consumable assembly for supplying filament to a 3D printer includes a spool-less filament coil, a payout tube, and a compressive band. The coil of filament is wound in a configuration having a generally cylindrical outer perimeter and an open interior; the coil has a payout hole extending from an inner layer of the coil to an outer layer of the coil and includes a filament strand configured to be withdrawn through the payout hole in response to a pull force, to thereby withdraw filament from the interior of the coil. The payout tube is disposed in the payout hole and provides a filament port. A compressive band is disposed over the outer layer and is configured to exert a compressive radial force on the coil so that the coil maintains its cylindrical shape without deformation, and the filament strand may be drawn through the filament outlet free of kinks, twists or tangles.

Abstract: A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly.

Abstract: An assembly for use in an additive manufacturing system to print a three-dimensional part that includes an extruder comprising a gear and a motor that turns the gear, wherein rotation of the gear regulates a flow of material out of the extruder. A controller, provides a control signal to the motor to control the rate at which the motor turns the at least one gear and incorporates a time-varying signal into the control signal to reduce ripples in the material output by the extruder.

Abstract: A liquefier assembly (20) for use in an additive manufacturing system (10) to print three-dimensional parts (22), which includes an upstream pressure-generating stage (52) and downstream flow-regulating stage (52). The upstream pressure-generating stage (52) includes a drive mechanism (46), a liquefier configured (52) to melt a consumable material (48) receive from the drive mechanism (46) to produce a molten material in a pressurized state. The downstream flow-regulating stage (52) includes a gear assembly (52) having a casing assembly (64,66,68) and a pair of gears (74,76) disposed within the interior cavity (78,80) and engaged with each other to regulate a flow of the pressurized molten material (48) through the gear assembly (52) for controlled extrusion.

Abstract: A spool assembly comprising a housing structure, a spool rotatably retained in an interior region of the housing structure, and a sealed sheath encasing the housing structure to define a barrier for the encased housing structure and the rotatably retained spool. The spool assembly further comprises a locking arm disposed outside of the sealed sheath and configured to operably engage the spool through the sealed sheath and through the housing structure in a manner that does not penetrate the sealed sheath, where the locking arm prevents the spool from rotating relative to the housing mechanism when operably engaged with the spool. The locking arm may disengage from the spool in a hands-free manner when the spool assembly is loaded into a bay of an additive manufacturing system.

Abstract: A liquefier assembly for use in an additive manufacturing system to print three-dimensional parts, which includes an upstream pressure-generating stage and downstream flow-regulating stage. The upstream pressure-generating stage includes a drive mechanism, a liquefier configured to melt a consumable material receive from the drive mechanism to produce a molten material in a pressurized state. The downstream flow-regulating stage includes a gear assembly having a casing assembly and a pair of gears disposed within the interior cavity and engaged with each other to regulate a flow of the pressurized molten material through the gear assembly for controlled extrusion.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system, the liquefier assembly comprising a downstream portion having a first average inner cross-sectional area, and an upstream having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion defining a shoulder configured to restrict movement of a melt meniscus of a consumable material.

Abstract: A spool assembly comprising a housing structure, a spool rotatably retained in an interior region of the housing structure, and a sealed sheath encasing the housing structure to define a barrier for the encased housing structure and the rotatably retained spool. The spool assembly further comprises a locking arm disposed outside of the sealed sheath and configured to operably engage the spool through the sealed sheath and through the housing structure in a manner that does not penetrate the sealed sheath, where the locking arm prevents the spool from rotating relative to the housing mechanism when operably engaged with the spool. The locking arm may disengage from the spool in a hands-free manner when the spool assembly is loaded into a bay of an additive manufacturing system.

Abstract: A spool assembly comprising a housing structure, a spool rotatably retained in an interior region of the housing structure, and a sealed sheath encasing the housing structure to define a barrier for the encased housing structure and the rotatably retained spool. The spool assembly further comprises a locking arm disposed outside of the sealed sheath and configured to operably engage the spool through the sealed sheath and through the housing structure in a manner that does not penetrate the sealed sheath, where the locking arm prevents the spool from rotating relative to the housing mechanism when operably engaged with the spool. The locking arm may disengage from the spool in a hands-free manner when the spool assembly is loaded into a bay of an additive manufacturing system.

Abstract: A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly.

Abstract: A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system, the liquefier assembly comprising a downstream portion having a first average inner cross-sectional area, and an upstream having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion defining a shoulder configured to restrict movement of a melt meniscus of a consumable material.

Abstract: A spool assembly for use in an additive manufacturing system, comprising a spool rotatably retained in a sealed sheath in a hub-less manner, and a locking mechanism configured to operably engage with the spool to prevent the spool from rotating.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system, the liquefier assembly comprising a downstream portion having a first average inner cross-sectional area, and an upstream having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion defining a shoulder configured to restrict movement of a melt meniscus of a consumable material.

Abstract: A method for building a three-dimensional model with an extrusion-based additive manufacturing system having an extrusion head, the method comprising depositing a consumable material from a liquefier assembly at an extrusion rate to substantially normalize a meniscus height within the liquefier assembly.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system, the liquefier assembly comprising a downstream portion having a first average inner cross-sectional area, and an upstream having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion defining a shoulder configured to restrict movement of a melt meniscus of a consumable material.

Abstract: A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly.

Abstract: A liquefier assembly for use in an extrusion-based additive manufacturing system, the liquefier assembly comprising a downstream portion having a first average inner cross-sectional area, and an upstream having a second average inner cross-sectional area that is less than the first inner cross-sectional area, the upstream portion defining a shoulder configured to restrict movement of a melt meniscus of a consumable material.

Abstract: A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly.