A process for forming a three-dimensional article in sequential layers in accordance with a digital model of the article. The process comprises the steps of defining a layer of a first liquid, applying a second liquid to the first liquid layer in a pattern corresponding to the digital model, and repeating these steps to form succesive layers. The first liquid comprises a first active component and the second liquid includes a second active component capable of reacting with the first reactive component so that the article is built up in layers.

Three-dimensional printing

An apparatus (10) for forming a three dimensional object (30) by layer-wise addition of a build material has a build-support (100) for supporting the object (30) during forming and a removable metallic base-layer (110) that is in the form of a mesh, film, sheet or foil. The base-layer (110) is removably securable to the build support (100).

Additive manufacturing apparatus and method

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

Method and apparatus for continuous composite three-dimensional printing

Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.

Methods for fiber reinforced additive manufacturing

Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to applying the filament from the conduit nozzle.

Apparatus for fiber reinforced additive manufacturing

An extrusion head (20) comprising at least one drive wheel (51) and an assembly (50) positionable between at least a first state and a second state. The assembly (50) comprises a first extrusion line (58) configured to engage the at least one drive wheel (51) while the assembly is positioned in the first state, and a second extrusion line (60) configured to engage the at least one drive wheel (51) while the assembly (50) is positioned in the second state.

Single-motor extrusion head having multiple extrusion lines

The present invention is a method for performing a calibration routine of a deposition device in a three-dimensional modeling machine that deposits a material to build up three-dimensional objects as directed by a controller on a substrate mounted on a platform. The method comprises generating a material build profile, which represents a three-dimensional structure at defined locations. A relative position of the material build profile is then determined. An expected build profile is identified and then compared to the determined relative position of the material build profile to identify any difference which represents an offset. The modeling system then positions the deposition device based upon the offset.

Auto tip calibration in an extrusion apparatus

A modeling apparatus (10) includes a platform (14) and a substrate (16), which are adapted to be releasably locked together to provide a surface for building up models in an additive-process three-dimensional modeling machine (12). The substrate (16) comprises a substantially rigid, non-dusting tray (50) providing a modeling surface (52). Male connectors extending from the tray are seated in male connectors in the platform (14), to engage the substrate (16) to the platform (14). The engaged substrate (16) is locked to the platform (14), maintaining accurate positioning of the substrate (16) while a model is built. After modeling is complete, the substrate (16) is released from the platform (14), the model is removed, and the substrate may be reused.

Modeling apparatus with tray substrate

An automated support cleaning system comprising a tank disposed within a housing and configured to circulate an aqueous cleaning solution to remove a support structure from a three-dimensional model.

Support cleaning system

A cassette for use in delivering a continuous length of filament. The cassette includes a housing having a first aperture and a spool rotatably mountable in the cassette housing. The spool contains a first female receptacle alignable with the first aperture, and a flexible boot is attached to the cassette housing and aligned with the first aperture. A removable plug is insertable through the first aperture and into the flexible boot for receipt within the first female receptacle of the spool to prevent rotation of the spool within the cassette housing.

Benjamin N. Dunn

Papers

Single-motor extrusion head having multiple extrusion lines

Auto tip calibration in an extrusion apparatus

Modeling apparatus with tray substrate

Support cleaning system

Cassette spool lock