A method may include fused filament fabricating a fused filament fabricated component by delivering a softened filament to selected locations at or adjacent to a build surface. The softened filament may include a binder and a primary material. The binder is configured to release a secondary material upon heating at or above a conversion temperature. The method also may include heating the fused filament fabricated component to a temperature at or above the conversion temperature to sinter the primary material to form a sintered part and cause the binder to release the secondary material within the sintered part.

A 3D printer successively fuses sheet material in a stack to form a three-dimensional object. The sheet material may provide a mesh separating islands of material that will be fused to produce the desired three-dimensional object. The mesh provides support for the island material during the fusing process and may be removed afterwards.

A system for building a three dimensional green compact comprising a printing station configured to print a mask pattern on a building surface, wherein the mask pattern is formed of solidifiable material; a powder delivery station configured to apply a layer of powder material on the mask pattern; a die compaction station for compacting the layer formed by the powder material and the mask pattern; and a stage configured to repeatedly advance a building tray to each of the printing station, the powder delivery station and the die compaction station to build a plurality of layers that together form the three dimensional green compact.

A system for building a three dimensional green compact comprising a printing station configured to print a mask pattern on a building surface, wherein the mask pattern is formed of solidifiable material; a powder delivery station configured to apply a layer of powder material on the mask pattern; a die compaction station for compacting the layer formed by the powder material and the mask pattern; and a stage configured to repeatedly advance a building tray to each of the printing station, the powder delivery station and the die compaction station to build a plurality of layers that together form the three dimensional green compact.

A 3-dimensional printing system for manufacturing a part is provided. The system includes a building platform having a deposited pattern of metal powder, a sand dispensing nozzle selectively supplying sand to the building platform, a binder dispensing nozzle selectively supplying binder material to the building platform, a robotic arm supporting one or more of the sand dispensing nozzle and the binder dispensing nozzle, the robotic arm moving the one or more of the sand dispensing nozzle and the binder dispensing nozzle, and a processor controlling the robotic arm to position the one or more of the sand dispensing nozzle and the binder dispensing nozzle relative to the deposited pattern of metal powder and control the sand dispensing nozzle and the binder dispensing nozzle to supply powdered sand and binder, respectively, based on a Computer Aided Drafting file associated with the part.

A 3-dimensional printing system for manufacturing a part is provided. The system includes a building platform having a deposited pattern of metal powder, a sand dispensing nozzle selectively supplying sand to the building platform, a binder dispensing nozzle selectively supplying binder material to the building platform, a robotic arm supporting one or more of the sand dispensing nozzle and the binder dispensing nozzle, the robotic arm moving the one or more of the sand dispensing nozzle and the binder dispensing nozzle, and a processor controlling the robotic arm to position the one or more of the sand dispensing nozzle and the binder dispensing nozzle relative to the deposited pattern of metal powder and control the sand dispensing nozzle and the binder dispensing nozzle to supply powdered sand and binder, respectively, based on a Computer Aided Drafting file associated with the part.

Certain exemplary embodiments can provide a manufacturing method, process, machine, and/or system for continuously consolidating granular materials, creating new alloys and/or composites, and/or modifying and/or refining material microstructure, by using plastic deformation of feedstock(s) provided in various structural forms. Materials produced during this process can be fabricated directly and/or in forms such as, e.g., wires, rods, tubes, sheets, plate and/or channels, etc.

Certain exemplary embodiments can provide a manufacturing method, process, machine, and/or system for continuously consolidating granular materials, creating new alloys and/or composites, and/or modifying and/or refining material microstructure, by using plastic deformation of feedstock(s) provided in various structural forms. Materials produced during this process can be fabricated directly and/or in forms such as, e.g., wires, rods, tubes, sheets, plate and/or channels, etc.

Certain exemplary embodiments can provide a manufacturing method, process, machine, and/or system for continuously consolidating granular materials, creating new alloys and/or composites, and/or modifying and/or refining material microstructure, by using plastic deformation of feedstock(s) provided in various structural forms. Materials produced during this process can be fabricated directly and/or in forms such as, e.g., wires, rods, tubes, sheets, plate and/or channels, etc.

An additive manufacturing machine is provided. The additive manufacturing machine includes a build unit including a powder dispenser assembly defining a powder reservoir that receives additive powder; a dosing rate measurement device in communication with the powder dispenser assembly, wherein the dosing rate measurement device measures a dosing rate of the additive powder in-situ; and a controllable device operably coupled to the build unit and including one or more processors configured to execute a program to cause the controllable device to adjust the dosing rate of the additive powder based on the dosing rate measured by the dosing rate measurement device.