Abstract: In various embodiments, a water-based binder solution for use in additive manufacturing, includes a thermoplastic binder. The thermoplastic binder includes a first polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 5,000 g/mol to less than or equal to 15,000 g/mol, a second polymer strand having a weight average molecular weight of from greater than or equal to 10,000 g/mol to less than or equal to 50,000 g/mol, and a third polymer strand having a weight average molecular weight of from greater than or equal to 1,000 g/mol to less than or equal to 5,000 g/mol. The binder solution further comprises from greater than or equal to 0.1 wt % to less than or equal to 5 wt % of a non-aqueous solvent having a boiling point of greater than 100° C.

Abstract: A binder comprises a monomer and an initiator. The monomer comprises at least one of a difunctional monomer and a monofunctional monomer. A method of manufacturing a part includes depositing a layer of particulate material on a working surface; selectively applying a binder in at least one of an edge of the layer of particulate material and an infill pattern representative of a stress of the object; repeating the steps of depositing and selectively applying to form a plurality of layers of particulate material with the applied binder; and exposing the plurality of layers of particulate material with the applied binder to an excitation source to decompose the initiator and initiate polymerization of the monomer to thereby form the green body part.

Abstract: Various embodiments provide a method of additively manufacturing a part including depositing a layer of a powder on a working surface, depositing a binder solution on the layer of the powder at first locations, and depositing a sintering aid solution on the layer of the powder at second locations. The sintering aid solution comprises a sintering aid in a solvent. In various embodiments, the sintering aid enables an increased brown strength as compared to parts containing unbound powder. The method enables binders that provide high green strength to be used at the edges of the part, while also balancing a shortened debind time with an increased brown strength. Embodiments in which binder solution is deposited according to a predetermined pattern at second locations are also described.

Abstract: Additive manufacturing apparatuses, components of additive manufacturing apparatuses, and methods of using such manufacturing apparatuses and components are disclosed. An additive manufacturing apparatus may include a recoat head for distributing build material in a build area, a print head for depositing material in the build area, one or more actuators for moving the recoat head and the print head relative to the build area, and a cleaning station for cleaning the print head.

Abstract: Additive manufacturing apparatuses are disclosed. In one embodiment, an additive manufacturing apparatus may comprise a support chassis including a print bay, a build bay, and a material supply bay. Each bay may comprise an upper compartment and a lower compartment. A working surface may separate each of the print bay, the build bay, and the material supply bay into the upper compartment and the lower compartment, wherein: the build bay may be disposed between the print bay and the material supply bay. The lower compartment of the build bay comprises bulkheads sealing the lower compartment of the build bay from the lower compartment of the print bay and the lower compartment of the material supply bay.

Abstract: An actuator assembly for distributing build material and depositing binder material in an additive manufacturing apparatus may comprise an upper support and a lower support spaced vertically spaced from one another. A recoat head actuator may be coupled to a recoat head and one of the upper support and the lower support. The recoat head actuator may include a recoat motion axis. The recoat head actuator effects bi-directional movement of the recoat head on the recoat motion axis. A print head actuator may be coupled to a print head and the other of the upper support and the lower support. The print head actuator may include a print motion axis. The print head actuator effects bi-directional movement of the print head on the print motion axis. The recoat motion axis and the print motion axis are parallel to one another and spaced apart from one another in the vertical direction.

Abstract: Build receptacles for additive manufacturing apparatuses are disclosed. The build receptacle may comprise a housing comprising a sidewall at least partially enclosing a build chamber. A build platform may be positioned within the build chamber. A position of the build platform may be slidably adjustable within the build chamber in a vertical direction from a lower position to one of a plurality of upper positions and from the one of the plurality of upper positions to the lower position. The build receptacle may further comprise a plurality of heating elements disposed around the build chamber.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: A method for forming an object includes moving a recoat assembly (200) in a coating direction over a build material, wherein the recoat assembly (200) comprises a first roller (202) and a second roller (204) that is spaced apart from the first roller; rotating the first roller (202) of the recoat assembly in a counter-rotation direction, such that a bottom of the first roller moves in the coating direction; contacting the build material with the first roller of the recoat assembly, thereby fluidizing at least a portion of the build material; irradiating, with a front energy source (260) coupled to a front end of the recoat assembly, an initial layer of build material positioned in a build area; subsequent to irradiating the initial layer of build material, spreading the build material on the build area with the first roller, thereby depositing a second layer of the build material over the initial layer of build material; and subsequent to spreading the second layer of the build material, irradiating, with a r

Abstract: A recoat assembly (200) for an additive manufacturing system includes a base member (250) that is movable in a lateral direction, a powder spreading member (202, 204) coupled to the base member (250), wherein the base member (250) at least partially encapsulates the powder spreading member (202, 204), and a vacuum (290) in fluid communication with at least a portion of the base member (250).

Abstract: An apparatus includes a printing head (154) comprising jet nozzles (158) spaced apart from one another, where a distance from a first jet nozzle to a second jet nozzle positioned adjacent the first jet nozzle defines a jet-spacing, a printing head position control assembly includes a first actuator assembly (102) to move the printing head along the longitudinal axis and a second actuator assembly (103) to move the printing head along a latitudinal axis, and an control unit communicatively coupled to the printing head position control assembly. The control unit causes jet nozzles to dispense drops of binder (50) while the printing head traverses a first pass trajectory along the longitudinal axis in a first direction, indexes the printing head to a second pass trajectory along the latitudinal axis, and causes jet nozzles to dispense drops of binder while the printing head traverses the second pass trajectory along the longitudinal axis in a second direction.

Abstract: A recoat assembly for an additive manufacturing system includes a first roller support, a second roller support, a first roller disposed between and supported by the first roller support and the second roller support, a first rotational actuator operably coupled to the first roller and configured to rotate the first roller about a first rotation axis, and a first sensor mechanically coupled to and in contact with the first roller support, where the first sensor outputs a first output signal indicative of a first force incident upon the first roller.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: A method of processing a part includes: identifying (2502) a location of at least one hole (62) disposed in the part using a computer-aided design (CAD) model of the part (36); aligning (2504) the part in a mounting system (56); 3D-scanning (2506) the part (36); detecting (2520) at least one boundary feature of the hole (36) based at least partially on at least one datum from 3D-scanning (2506) the part; and generating (2536) a first toolpath (92) based at least partially on the boundary feature.

Abstract: A method of manufacturing comprises depositing a layer of a powder on a working surface and selectively depositing a water-based binder solution comprising from 0.1 wt % to 5 wt % of a non-aqueous solvent having a boiling point of greater than 100° C. and less than or equal to 175° C. at 1 atm and a thermoplastic binder comprises a first polymer strand including a first functional group and a second polymer strand including a second functional group into the layer of powder in a pattern representative of a structure of a part. The method further comprises non-covalently coupling the first and second polymer strands together via interaction between the first and second functional groups to form a green body part.

Abstract: A binder solution comprises greater than or equal to 0.5 wt % and less than or equal to 20 wt % of nanoparticles, a thermoplastic binder, and a solvent. The nanoparticles may comprise metallic nanoparticles comprising nickel, silver, chromium, aluminum, cobalt, iron, or combinations thereof. The nanoparticles may comprise ceramic nanoparticles, the comprising alumina, aluminum nitride, zirconia, titania, silica, silicon nitride, silicon carbide, boron nitride, or combinations thereof. A method of manufacturing a part includes depositing a layer of particulate material on a working surface, applying a binder solution into the layer of particulate material in a pattern, repeating the steps of depositing and selectively applying to form a plurality of layers of particulate material with the applied binder solution, and curing the applied binder solution in the plurality of layers of particulate material with the applied binder solution to evaporate the solvent and thereby form a green body part.