Layers of build and support material on an intermediate transfer surface are moved past a transfuse station and a platen moves relative to the intermediate transfer surface to contact the platen to one of the layers on the intermediate transfer surface. The intermediate transfer surface transfers a layer of the build material and the support material to the platen each time the platen contacts the layers on the intermediate transfer surface at the transfuse station to successively form a freestanding stack of the layers of build and support material on the platen. The build material has a higher melting temperature than the support material. A support material removal station heats the stack to a temperature above the melting temperature of the support material, but below the melting temperature of the build material, to melt the support material, but leave a 3-D structure made of only the build material.

An additive manufacturing method produces a 3D part utilizes electrophotography-based additive manufacturing and molding processes. A layered structure having a cavity is printed on a build platform using at least one electrophotographic (EP) engine to develop imaged layers of powder material, and a transfusion assembly to stack and fuse the imaged layers on the build platform. Molding material is deposited into the cavity as the layered structure is printed, using a deposition unit. The molding material solidifies to form at least a portion of the 3D part, which may also include portions formed from imaged powder material.

A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having a semi-crystalline thermoplastic material and a charge control agent. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.

A management system according to the aspect of the embodiments performs expiration date management of consumables delivered for a forming apparatus to be managed, based on an expiration date for consumption after manufacturing of each consumable and an expiration date for consumption after opening of each consumable. The management system then automatically makes arrangement for collecting expired consumables.

A support material contains at least one member selected from the group consisting of low molecular weight saccharides, polyvinyl alcohols, and polyalkylene glycols; non-water-soluble cellulose fibers; and a water-soluble cellulose derivative.

A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

Methods and devices use a three-dimensional scanner and a three-dimensional printing device operatively connected to a processor. The three-dimensional scanner automatically determines a size and shape of an item to be packaged and the processor automatically identifies information corresponding to the item to be packaged. The processor automatically controls the three-dimensional printing device to form a container that is customized to match the size and shape of the item to be packaged (using a continuous additive process of forming successive layers of material in different shapes). When forming the container, the processor also automatically controls the three-dimensional printing device to form a label as part of the container. The label includes color variations to visually convey the information identified by the processor.

A platen assembly for use in an additive manufacturing system, which includes a platen plate that is preferably secured to a gantry mechanism of the additive manufacturing system, and having a top surface, and one or more magnets secured to the platen plate and configured to generate one or more magnetic fields at the top surface of the platen plate. The platen gantry is configured to magnetically couple interchangeable and replaceable build sheets to the top surface of the platen plate due to the one or more generated magnetic fields, and where the magnetically-coupled build sheets are configured to receive the printed layers from the printing mechanism.

A method of determining a value of density of a heat absorbing agent to be applied to a target pixel on a medium, wherein the medium is distended, when heated, the value of density of the heat absorbing agent is a density value of the heat absorbing agent that is applied to the medium before heated, and density values of the heat absorbing agent are set for plural pixels on the medium, the method comprising, calculating a first average density value of first plural pixels in the vicinity of the target pixel among the plural pixels, calculating a second average density value of second plural pixels in the vicinity of the target pixel, and determining a density value of the heat absorbing agent based on the calculated first average density value and second average density value, when a density value applied to the target pixel satisfies a first prescribed condition.

A method for printing a three-dimensional part with an additive manufacturing system includes providing a consumable feedstock material comprising a semi-crystalline polymer containing one or more secondary materials, wherein the consumable feedstock material has a process window in which crystalline kinetics are either accelerated or retarded. The consumable feedstock material is melted in the additive manufacturing system. At least a portion of the three-dimensional part from the melted consumable feedstock material in a build environment maintained within the process window.