A method of making a foamed article comprises (a) injection molding a molten thermoplastic elastomer to form an precursor; (b) crosslinking the thermoplastic elastomer; (c) heating the thermoplastic elastomer to a first temperature to soften the thermoplastic elastomer; (d) infusing the thermoplastic elastomer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic elastomer; and (e) while the article is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

A method of making a foamed article comprises (a) injection molding a molten thermoplastic elastomer to form an precursor; (b) crosslinking the thermoplastic elastomer; (c) heating the thermoplastic elastomer to a first temperature to soften the thermoplastic elastomer; (d) infusing the thermoplastic elastomer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic elastomer; and (e) while the article is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.

A method for producing a tubular body with reduced internal stress uses 3D printing. The tubular body has an outer wall with a stiffening structure extending along at least part of the outer wall. The method sets a printing plane for 3D printing with a 3D printer, and prints a tubular body layer in the printing plane with the 3D printer. The tubular body layer has an outer wall layer and a stiffening structure layer extending in the printing plane along a periphery of the outer wall layer. The stiffening structure layer has at least two portions spaced apart from one another. The method produces an outer wall with a stiffening structure for a tubular body with reduced internal stress.

A method for producing a tubular body with reduced internal stress uses 3D printing. The tubular body has an outer wall with a stiffening structure extending along at least part of the outer wall. The method sets a printing plane for 3D printing with a 3D printer, and prints a tubular body layer in the printing plane with the 3D printer. The tubular body layer has an outer wall layer and a stiffening structure layer extending in the printing plane along a periphery of the outer wall layer. The stiffening structure layer has at least two portions spaced apart from one another. The method produces an outer wall with a stiffening structure for a tubular body with reduced internal stress.

A single-step method of generating a three dimensional (3D) printed article includes: selecting a first metastructure and a second metastructure; designing and constructing a first transitional metastructure that transitions from the first metastructure to the second metastructure; depositing a first layer comprising the first metastructure; seamlessly connecting the first and first transitional metastructures by depositing a first transitional layer comprising the first transitional metastructure on the first layer; and seamlessly connecting the first transitional and second metastructures by depositing a second layer comprising the second metastructure on the first transitional layer.

A single-step method of generating a three dimensional (3D) printed article includes: selecting a first metastructure and a second metastructure; designing and constructing a first transitional metastructure that transitions from the first metastructure to the second metastructure; depositing a first layer comprising the first metastructure; seamlessly connecting the first and first transitional metastructures by depositing a first transitional layer comprising the first transitional metastructure on the first layer; and seamlessly connecting the first transitional and second metastructures by depositing a second layer comprising the second metastructure on the first transitional layer.

An apparatus for producing endless 3-D printed belts using in papermaking and an apparatus for producing endless 3-D printed belts laminated to a substrate for additional strength and dimensional stability during use.

An apparatus for producing endless 3-D printed belts using in papermaking and an apparatus for producing endless 3-D printed belts laminated to a substrate for additional strength and dimensional stability during use.