Stratasys, Inc.

Stratsys, Inc.

Michael D Bosveld

William J Swanson

Dominic F Mannella

Robert L Skubic

Joseph Edward LaBossiere

Robert E Styer

Thomas P Paul

J Samuel Batchelder

John Samuel Batchelder

Kevin C Johnson

James W Comb

S Scott Crump

Paul J Leavitt

Ronald G Schloesser

John A Bushey

Jerome W Goetzke

Chad E Beery

Benjamin L Braton

Logan R Kiene

David G Bocek

Jeffery J Hanson

Richard Thomas Anderson

Brent Jorgenson

David Mulcrone

Max Peters

Joseph E Labossiere

Jason Robert Nixon

Zachary Mady

Mark Schletty

Charles Alan Smithson

Thomas Peter Paul

Richard T Anderson

Joseph E La Bossiere

A method of additive manufacturing comprises operating an additive manufacturing system for fabricating a multiplicity of objects, while acquiring a set of images during fabrication of each of the objects. For each object, a respective set of images is analyzed to identify fabrication irregularities, and a fabrication score is generated based on the irregularities. The multiplicity of objects is clustered according to the fabrication scores into at least two clusters.

Method and system for classifying additive manufactured objects

A method for calibrating a 3D printer includes the steps of providing information obtained in a factory calibration indicating a center of an inner diameter of a tip orifice in a metal extrusion nozzle and a center of a tip surface for the nozzle and inductively sensing the nozzle with an eddy current sensor when secured to a print head on a gantry or robotic arm of the 3D printer to identify a sensed location of the center of the tip surface of the nozzle. The method includes determining a location of the center of the inner diameter of the tip orifice on the nozzle on the print head and utilizing the provided information to locate the center of the inner diameter of the tip orifice.

Tip calibration in an additive manufacturing system

An induction sensing method for identifying the center of a tip surface of a nozzle of print head of a 3D printer includes providing an eddy current sensor in a fixed position and providing a metal nozzle with a tip orifice in a main body and a tip surface about the tip orifice. The method includes moving the metal nozzle over the eddy current sensor in a predetermined motion path above the eddy current sensor while the eddy current sensor remains stationary and samples the magnitude of inductance in a generated inductive field, thereby generating a curve representing the inductive field. The method includes identifying a maximum amplitude of the curve to identify the center of the tip surface.

Induction sensing method for locating center of metallic nozzle tip

A probe for an additive manufacturing system includes a probe body having a first air port therethrough between an inlet and an outlet, and a location sensing probe extending from the probe body. The location sensing probe includes a probe end and a probe bar, the probe bar coupled between the probe body and the probe end, and a channel surrounding the probe bar, the channel having an inner tube having an inlet proximate the probe body and an outlet proximate the probe end. A method of determining a position of an item being printed in an additive manufacturing system, includes probing the position with a location sensing probe having a resolution finer than a print resolution of the print head.

Method of using a support structure as a fiducial for measuring position

An additive manufacturing system includes an extruder that includes a drive mechanism, a nozzle, and a pressure sensor. The drive mechanism is configured to feed a molten consumable material. The nozzle is attached at a distal end of the extruder and includes a nozzle tip, through which the molten consumable material is discharged as an extrudate. A pressure interface is fluidically coupled to an interior cavity of the nozzle. The pressure sensor is configured to operably measure a pressure within the interior cavity of the nozzle through the pressure interface.

Pressure sensing in an additive manufacturing system

An additive manufacturing system includes an extruder having a motor and a pressure sensor. A filter receives speed values for the motor and generates a predicted pressure value from the speed values. A response threshold module sets a response threshold pressure value based on the predicted pressure value such that when the response threshold pressure value is between a pressure value from the pressure sensor and the predicted pressure value, a response is executed.

Predictive flow control responses in an additive manufacturing system

A method for printing a three-dimensional part with an additive manufacturing system, the method comprising generating and printing a planarizing part having a substantially-planar top surface relative to a build plane, and a bottom surface that substantially mirrors a topography of a platen surface, and printing the three-dimensional part over the substantially-planar top surface of the printed planarizing part.

Platen planarizing process for additive manufacturing system

A starter piece for printing a three-dimensional item includes a main body having a face surface, a keel coupled to the main body, a guide tab extending from the keel, and at least one retaining mechanism coupled to the main body. Printing a three-dimensional item with an additive manufacturing system having a print foundation, a print head configured to print the three-dimensional item, and a plurality of support rails includes printing a support structure for the three-dimensional item in a layer by layer manner along the printing axis along with the printing of the three-dimensional item. The support structure is printed to provide a support between the three-dimensional item and the plurality of support rails of the additive manufacturing system.

Starter piece and printing methods for additive manufacturing system

Method for printing a three-dimensional part layerwise with an additive manufacturing system includes printing layers by depositing material from a print head onto a print foundation, incrementing a position of the print head relative to the print foundation after each layer is printed, and indexing the print foundation carrying the printed layers away from the print head along the printing axis after a number of layers are printed. Printing is performed with driven and fixed rails clamped against movement of the print foundation. Moving the print foundation includes moving the driven rails with respect to the fixed rails in a direction substantially perpendicular to the build plane. Additive manufacturing system includes a drive mechanism to index the print foundation on the printing axis using fixed and driven rails, the driven rails engaging the print foundation for moving the print foundation.

Print foundation positioning and printing methods for additive manufacturing system

An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.

Additive manufacturing system with extended printing volume, and methods of use thereof

Material hopper

In-situ part position measurement

Growing community of inventors

Bloomington, MN, United States of America

Michael D Bosveld