Abstract: Disclosed herein is a system for printing a three-dimensional object. The system can include at least one nozzle assembly configured to receive a continuous fiber and at least partially encase the continuous fiber with a polymer material to create a composite material. The nozzle assembly can also include a liquefier assembly that is operable coupled to a nozzle, which is configured to allow for the controlled deposit of the composite material while minimizing or eliminating tension exerted on the continuous fiber.

Abstract: Disclosed herein is a system for printing a three-dimensional object. The system can include at least one nozzle assembly configured to receive a continuous fiber and at least partially encase the continuous fiber with a polymer material to create a composite material. The nozzle assembly can also include a liquefier assembly that is operable coupled to a nozzle, which is configured to allow for the controlled deposit of the composite material while minimizing or eliminating tension exerted on the continuous fiber.

Abstract: A composite fiber for use in additive manufacturing such as fused filament fabrication is described along with methods of its construction and use. The composite fiber includes a single continuous fiber (e.g., a continuous carbon roving) and a polymer (e.g., a high glass transition polymer) in intimate contact. The composite fiber is formed through immersion of the continuous fiber in a series of two or more solutions that together include monomer(s), catalysts, or other materials for generating the polymer as the continuous fiber moves through the solutions.

Abstract: Embodiments disclosed herein are directed to systems and methods for producing high quality 3-dimensional prints using various materials. Aspects of the present disclosure may provide particular advantages when used with high temperature thermoplastics (such as polyetherimide (PEI) polymers), such as when using continuous fibers impregnated with a high temperature thermoplastic, or when co-depositing a continuous fiber with a formation material containing a high temperature thermoplastic.

Abstract: A composite filament for use in additive manufacturing such as fused filament fabrication is provided, along with methods of its construction, and use incorporation application of sonic energy during the composite filament during initial formation. The composite filament allows for formation of work pieces having a complicated shape that can incorporate continuous filaments in multiple directions and orientations, which can lead to the production of stronger and more useful composite structures.

Abstract: A composite fiber for use in additive manufacturing such as fused filament fabrication is described along with methods of its construction and use. The composite fiber includes a single continuous fiber (e.g., a continuous carbon roving) and a polymer (e.g., a high glass transition polymer) in intimate contact. The composite fiber is formed through immersion of the continuous fiber in a series of two or more solutions that together include monomer(s), catalysts, or other materials for generating the polymer as the continuous fiber moves through the solutions.

Abstract: A composite filament for use in additive manufacturing such as fused filament fabrication is described along with methods of its construction and use. The composite filament includes a single continuous filament (e.g., a continuous carbon roving) and a polymer (e.g., a high glass transition polymer) in intimate contact. The composite filament is formed through immersion of the continuous filament in a solution of the polymer. The composite filament can be combined with an additional formation material in an additive manufacturing process.

Abstract: A part includes a continuous fiber substantially encased in a formation material. The fiber and formation material are arranged in a plurality of alternating layers such that the formation material of a first one of the alternating layers adheres to the formation material of a second one of the alternating layers over the length of the continuous fiber. The part may include a thin-walled hollow member such as a duct. In some embodiments a part comprises a continuous fiber prepared by an additive manufacturing process comprising the steps of: depositing a composite material on a print bed using a print head, the composite material comprising a continuous fiber and a formation material in intimate contact with the continuous fiber; moving the print head and/or the print bed during the depositing of the composite material; and consolidating the composite material.

Abstract: Embodiments disclosed herein are directed to systems and methods for producing high quality 3-dimensional prints using various materials. Aspects of the present disclosure may provide particular advantages when used with high temperature thermoplastics (such as polyetherimide (PEI) polymers), such as when using continuous fibers impregnated with a high temperature thermoplastic, or when co-depositing a continuous fiber with a formation material containing a high temperature thermoplastic.

Abstract: Disclosed herein is a system for printing a three-dimensional object. The system can include at least one nozzle assembly configured to receive a continuous fiber and at least partially encase the continuous fiber with a polymer material to create a composite material. The nozzle assembly can also include a liquefier assembly that is operable coupled to a nozzle, which is configured to allow for the controlled deposit of the composite material while minimizing or eliminating tension exerted on the continuous fiber.

Abstract: A part includes a continuous fiber substantially encased in a formation material. The fiber and formation material are arranged in a plurality of alternating layers such that the formation material of a first one of the alternating layers adheres to the formation material of a second one of the alternating layers over the length of the continuous fiber. The part may include a thin-walled hollow member such as a duct. In some embodiments a part comprises a continuous fiber prepared by an additive manufacturing process comprising the steps of: depositing a composite material on a print bed using a print head, the composite material comprising a continuous fiber and a formation material in intimate contact with the continuous fiber; moving the print head and/or the print bed during the depositing of the composite material; and consolidating the composite material.

Abstract: A composite filament for use in additive manufacturing such as fused filament fabrication is described along with methods of its construction and use. The composite filament includes a single continuous filament (e.g., a continuous carbon roving) and a polymer (e.g., a high glass transition polymer) in intimate contact. The composite filament is formed through immersion of the continuous filament in a solution of the polymer. The composite filament can be combined with an additional formation material in an additive manufacturing process.