A system and method for providing three-dimensional printing is disclosed. The three-dimensional printing technology includes enhanced functionality to provide better resolution printing, filtration of forming materials stored within a reservoir tank, and a simple and efficient cleaning process to remove debris from the reservoir subsequent to a printing cycle.

A method of assembling components of a vehicle is provided that includes locating a node (20) relative to an adjoining component (22), measuring at least one geometrical feature of the node or the adjoining component, 3D printing an assembly adjustment member (24) based on the measuring, and placing the assembly adjustment member proximate at least one of the node or the adjoining component. The assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.

An additive manufactured structure and methods for making and using same. The structure includes a plurality of layers stacked in a stacking direction. The structure further includes at least one reinforcement structure affixed to the layers and extending at least partially in the stacking direction. The reinforcement structure can hold the layers together to stiffen and strengthen the structure. Mechanical strength of the structure in the stacking direction can advantageously be improved. Shape and spatial distribution of the reinforcement structure can be customized and adapted to the geometry of the layers to enhance strengthening effect. The reinforcement structure can be tension free or have a compressive stress induced by a preload applied during manufacturing. The compressive stress can be adjusted dynamically via a sensor. The structure and methods provide, among other things, novelty for addressing the inherent weaknesses in parts created by large-scale extrusion deposition processes.

An additive manufactured structure and methods for making and using same. The structure includes a plurality of layers stacked in a stacking direction. The structure further includes at least one reinforcement structure affixed to the layers and extending at least partially in the stacking direction. The reinforcement structure can hold the layers together to stiffen and strengthen the structure. Mechanical strength of the structure in the stacking direction can advantageously be improved. Shape and spatial distribution of the reinforcement structure can be customized and adapted to the geometry of the layers to enhance strengthening effect. The reinforcement structure can be tension free or have a compressive stress induced by a preload applied during manufacturing. The compressive stress can be adjusted dynamically via a sensor. The structure and methods provide, among other things, novelty for addressing the inherent weaknesses in parts created by large-scale extrusion deposition processes.

According to some embodiments, a computer processor may receive an item definition file containing a volumetric description of the three-dimensional item and create a compressed item definition file including a compressed volumetric description of the three-dimensional item. For example, the item definition file may include a plurality of item slices, from a bottom item slice to a top item slice, each item slice describing a two-dimensional portion of the three-dimensional item. For at least some of the item slices, the computer processor may encode data in the item definition file describing a particular item slice in terms of differences between that particular item slice and another item slice (e.g., a neighboring item slice directly below that particular item slice or an anchor item slice below that particular item slice).

According to some embodiments, a computer processor may receive an item definition file containing a volumetric description of the three-dimensional item and create a compressed item definition file including a compressed volumetric description of the three-dimensional item. For example, the item definition file may include a plurality of item slices, from a bottom item slice to a top item slice, each item slice describing a two-dimensional portion of the three-dimensional item. For at least some of the item slices, the computer processor may encode data in the item definition file describing a particular item slice in terms of differences between that particular item slice and another item slice (e.g., a neighboring item slice directly below that particular item slice or an anchor item slice below that particular item slice).

An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple layers during the build of 3D printing. The device includes a penetrating extension that fits within the void to create a vertical strengthening feature via heat and/or extruded fill material. The size and/or movement of the heated extension can impact the void side walls to reflow the build material and blend the layers together within the void side walls.

An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple layers during the build of 3D printing. The device includes a penetrating extension that fits within the void to create a vertical strengthening feature via heat and/or extruded fill material. The size and/or movement of the heated extension can impact the void side walls to reflow the build material and blend the layers together within the void side walls.

The problem of limited throughput in three-dimensional (3D) printing processes is addressed by systems and methods that employ mirrors to receive energy reflected by the melt pool and to redirect such light back to the melt pool, where it may further heat the melt pool. Multiple such passes of reflection from the melt pool and redirection back to the melt pool may substantially increase the efficiency at which the melt pool absorbs the energy, thereby substantially increasing the throughput of the 3D printing process.

A self-cleaning screen is formed via additive printing. The dimensions of the self-cleaning screen are modified. Supports are printed via additive printing. The supports are formed over a plurality of wires. Side seals may be additively printed along major sides of the plurality of wires. Wear of the screens is monitored.