Abstract: A method and apparatus for additive manufacturing that applies a magnetic field to reduce undesirable imperfections, such as voids or air pockets, in a deposited working material. The apparatus includes a nozzle for extruding a plastic material and a supply of polymeric working material provided to the nozzle, wherein the polymeric working material is magnetically susceptible and/or electrically conductive, and a magneto-dynamic heater for producing a time varying, high flux, frequency sweeping, alternating magnetic field in the vicinity of the nozzle and/or the deposited working material to penetrate into working material to reflow or constrict at least portions of the material through at least one of an induced transient magnetic domain and an induced, annular current.

Abstract: A method for producing a polymer composite fiber comprised of a polymer matrix with filaments incorporated therein whose lengthwise dimensions are substantially oriented with the axial dimension of the composite fiber, the method comprising subjecting a melt comprised of a polymer matrix and filaments to an extrusion process in which the melt is extruded into a fibrous form in the absence of screw extruders and in the substantial absence of shear forces that result in breakage of the filaments, followed by cooling and solidification of the extruded melt to provide the polymer composite fiber. Integration of these polymer composite fibers with additive manufacturing technologies, particularly rapid prototyping methods, such as FFF and 3D printing, are also described. The resulting polymer composite fibers and articles made thereof are also described.

Abstract: A manufactured component, method and apparatus for advanced manufacturing that includes a polymeric working material formed into a mandrel with a carbon fiber overlay formed in a continuation of the process. The mandrel build and the carbon fiber overlay of the component preferably take place at atmospheric temperatures.

Abstract: A specimen for measuring a material under multiple strains and strain rates. The specimen including a body having first and second ends and a gage region disposed between the first and second ends, wherein the body has a central, longitudinal axis passing through the first and second ends. The gage region includes a first gage section and a second gage section, wherein the first gage section defines a first cross-sectional area that is defined by a first plane that extends through the first gage section and is perpendicular to the central, longitudinal axis. The second gage section defines a second cross-sectional area that is defined by a second plane that extends through the second gage section and is perpendicular to the central, longitudinal axis and wherein the first cross-sectional area is different in size than the second cross-sectional area.

Abstract: Methods and compositions for additive manufacturing that include reactive or thermosetting polymers, such as urethanes and epoxies. The polymers are melted, partially cross-linked prior to the depositing, deposited to form a component object, solidified, and fully cross-linked. These polymers form networks of chemical bonds that span the deposited layers. Application of a directional electromagnetic field can be applied to aromatic polymers after deposition to align the polymers for improved bonding between the deposited layers.

Abstract: A manufactured component, method and apparatus for advanced manufacturing that includes a nozzle for extruding a working material, wherein the polymeric working material includes a carbon fiber reinforced polymer. The build of the component takes place on a work surface at atmospheric temperatures.

Abstract: A method and apparatus for additive manufacturing that includes a nozzle and/or barrel for extruding a plastic material and a supply of polymeric working material provided to the nozzle, wherein the polymeric working material is magnetically susceptible and/or electrically conductive. A magneto-dynamic heater is provided for producing a time varying, high flux, frequency sweeping, alternating magnetic field in the vicinity of the nozzle to penetrate into and couple the working material to heat the material through at least one of an induced transient magnetic domain and an induced, annular current.

Abstract: A method and apparatus for additive manufacturing that includes a nozzle for extruding a plastic material and a supply of polymeric working material provided to the nozzle, wherein the polymeric working material is magnetically susceptible and/or electrically conductive. A magneto-dynamic heater is provided for producing a time varying, high flux, frequency sweeping, alternating magnetic field in the vicinity of the nozzle to penetrate into and couple the working material to heat the material through at least one of an induced transient magnetic domain and an induced, annular current.

Abstract: A specimen for measuring a material under multiple strains and strain rates. The specimen including a body having first and second ends and a gage region disposed between the first and second ends, wherein the body has a central, longitudinal axis passing through the first and second ends. The gage region includes a first gage section and a second gage section, wherein the first gage section defines a first cross-sectional area that is defined by a first plane that extends through the first gage section and is perpendicular to the central, longitudinal axis. The second gage section defines a second cross-sectional area that is defined by a second plane that extends through the second gage section and is perpendicular to the central, longitudinal axis and wherein the first cross-sectional area is different in size than the second cross-sectional area.