A powder bed fusion system is provided. The system comprises a build area with a movable build plate. Two powder overflow and extraction (POE) chambers flank the build area on opposite sides. Two dispensing chambers flank the POE chambers, opposite the build area. Two reservoir chambers flank the dispensing chambers, opposite the POE chambers. A recoater device is configured to move build material from the dispensing chambers or reservoir chambers to the build area. An energy source is configured to generate an energy beam. An energy beam positioning device is configured to selectively direct the energy beam within the build area. A controller is programmed to control, according to a 3D model of a part, the energy source, energy beam positioning device, recoater device, build plate, and vertically movable plates within the POE chambers, dispensing chambers, and reservoir chambers.

A method for producing a functionally graded component layer-by-layer includes: depositing radiant-energy-curable resin on a build surface defined by a resin support, the resin containing filler including at least two groups of particles with different physical properties; allowing the filler to settle such that the groups of particles separate from each other, defining at least two regions within the resin; positioning a stage relative to the build surface so as to define a layer increment in the resin; selectively curing the resin using an radiant energy applied in a specific pattern so as to define the geometry of a cross-sectional layer of the component; moving the build surface and the stage relatively apart so as to separate the component from the build surface; repeating at least the steps of positioning and selectively curing for a plurality of layers, until the component is complete.

An additive manufacturing system, in particular a 3D printer, including a bottom element. The bottom element includes at least one funnel and/or air outlet, wherein at least one sieve and/or grid element is arranged in the area of the funnel and a plate element is arranged opposite the sieve.

An additive manufacturing system, in particular a 3D printer, including a bottom element. The bottom element includes at least one funnel and/or air outlet, wherein at least one sieve and/or grid element is arranged in the area of the funnel and a plate element is arranged opposite the sieve.

A filament or printing material placed in a syringe for 3D printing comprising polymers, proteins, and/or functional particles and materials is provided. Methods of treating a bone defect in a subject in need thereof comprising using a handheld 3D printer to apply a filament or the printing material placed in a syringe to the bone defect of the subject are also provided. Methods of fixing or gluing natural or synthetic bone grafts using a handheld 3D printer to apply a filament or the printing material placed in a syringe over and around the defect or at the interface of a flap and the bone. Methods of printing a graft cage for retaining bone grafts and/or bone graft substitute in its desired location during healing for treatment of critical-sized segmental defects in long bones are provided.

An extrusion head for a three-dimensional printer is disclosed including a feed tube, a heater, a cooler, and a bridge. The feed tube can be made of metal and has an inlet for receiving a forwardly driven filament of solid deposition material, an outlet, a downstream portion adjacent to the outlet, an upstream portion upstream from the downstream portion, and an internal passage extending from the inlet to the outlet. The heater is thermally coupled with the downstream portion of the feed tube for heating a filament to provide softened fluid deposition material. The cooler is thermally coupled with the upstream portion and spaced generally axially from the heater to define a generally axially extending gap traversed by the feed tube. The bridge traverses the gap and provides a rigid mechanical connection between the heater and the cooler.

A modular system for performing additive manufacturing of an object includes at least two additive manufacturing devices, each having a housing with two slots on lateral sides to accommodate a manufacturing tray; a printer head and axis system; and a movement mechanism. A control module is operatively coupled to each of the at least two additive manufacturing devices. The control module is configured to control the at least two additive manufacturing devices to arrange the manufacturing tray in a first of the at least two additive manufacturing devices; print a part of the object on the manufacturing tray arranged in the first additive manufacturing device; move the manufacturing tray having the partially manufactured object to a second of the at least two additive manufacturing devices; and print a remaining part of the object on the manufacturing tray to complete the additive manufacturing of the object.

A modular system for performing additive manufacturing of an object includes at least two additive manufacturing devices, each having a housing with two slots on lateral sides to accommodate a manufacturing tray; a printer head and axis system; and a movement mechanism. A control module is operatively coupled to each of the at least two additive manufacturing devices. The control module is configured to control the at least two additive manufacturing devices to arrange the manufacturing tray in a first of the at least two additive manufacturing devices; print a part of the object on the manufacturing tray arranged in the first additive manufacturing device; move the manufacturing tray having the partially manufactured object to a second of the at least two additive manufacturing devices; and print a remaining part of the object on the manufacturing tray to complete the additive manufacturing of the object.

Provided is a three-dimensional shaped object manufacturing method. The manufacturing method includes a first step of generating intermediate data including (i) path data indicating, by a plurality of partial paths, a path through which the discharge unit discharges a shaping material while being moved and (ii) discharge control data including at least one of discharge amount information indicating a discharge amount of the shaping material in each of the partial paths and moving speed information indicating a moving speed of the discharge unit in each of the partial path, a second step of analyzing the intermediate data to specify a gap portion interposed between a first partial path and a second partial path, a third step of generating shaping data from the intermediate data by changing the discharge control data corresponding to the second partial path so as to increase, in the second partial path, a width of the shaping material stacked on a stage or on a layer that is previously formed, and a fourth step of shaping a three-dimensional shaped object by controlling the discharge unit according to the shaping data.

A system and method for applying patterns to surfaces. A pattern may be applied to a surface of an object using a three-dimensional (3D) printer system. The 3D printer system may include a printer head including an applicator holding material used to form the pattern on the surface, a structure configured to hold a substrate to which the material will be applied, and a controller for adjusting a location of the printer head relative to a surface and initiating applying material from the applicator onto the surface. The applicator may be a syringe with a needle. 3D coordinates at which material is to be applied to a surface to form the pattern may be determined and identified based on a relative location of the substrate and the pattern. The pattern may be a speckle dot pattern used in Digital Image Correlation (DIC) material testing and characterization techniques.