A method of fabricating an object, comprising direct depositing a first layer of first object material on a support substrate electrode; applying a conductive agent material onto the first layer; direct depositing a first layer of charged powder onto the first layer on the support substrate electrode, to form a first powder layer on the first layer on the support substrate electrode. Multiple powder layers may be direct deposited on the first layer. The method may be further comprised of fusing the powder layer(s) to form a first fused layer on the support substrate electrode. A related object fabrication apparatus is also disclosed.

A method of fabricating an object, comprising direct depositing a first layer of first object material on a support substrate electrode; applying a conductive agent material onto the first layer; direct depositing a first layer of charged powder onto the first layer on the support substrate electrode, to form a first powder layer on the first layer on the support substrate electrode. Multiple powder layers may be direct deposited on the first layer. The method may be further comprised of fusing the powder layer(s) to form a first fused layer on the support substrate electrode. A related object fabrication apparatus is also disclosed.

A method of depositing a multiphase material. The method includes providing a Continuous Multifunctional Composite (CMC) phase containing at least one continuous element in a polymeric matrix, passing the CMC phase through a feeding system containing a cutting system, producing a predetermined length of the CMC phase, providing a flow a molten polymer such that the molten polymer and the CMC phase are merged into a continuous co-extrusion nozzle so as to produce a co-extruded multiphase material, and depositing the co-extruded multiphase material onto a surface. An apparatus for depositing a multiphase material. The apparatus contains a co-extrusion nozzle, a means to introduce a CMC phase and a molten polymer into the co-extrusion nozzle, such that the molten polymer and the CMC phase are co-extruded and deposited on a surface. An article containing a CMC phase containing continuous elements embedded in a polymer resin forming a multiphase structure.

A powder recirculation system for an apparatus for manufacturing a three-dimensional object (500) from powder is provided. The powder recirculation system comprises: a delivery path coupled to an outlet of a powder tank (410), the powder tank configured to store the powder; a powder repository (115) coupled to an outlet of the delivery path, the delivery path comprising a delivery mechanism for delivering the powder from the powder tank to the powder repository; a powder recirculation path coupled to an outlet (102) of the powder repository, wherein the powder recirculation path is configured to return first excess powder from the powder repository to the delivery path at a location (103, 104) upstream of the outlet of the powder tank.

Provided is a three-dimensional shaping apparatus comprising a nozzle having a discharge port through which a shaping material is discharged, and a flow rate regulation mechanism that includes a butterfly valve provided in a flow path upstream of the discharge port.

Provided is a three-dimensional shaping apparatus comprising a nozzle having a discharge port through which a shaping material is discharged, and a flow rate regulation mechanism that includes a butterfly valve provided in a flow path upstream of the discharge port.

In a method for manufacturing a three-dimensional shaped object, when an amount of a shaping material discharged toward a shaping surface per unit movement amount of a discharging unit is defined as a discharged shaping amount, in a layer forming step of forming a layer on the shaping surface, in a case in which a second partial shaped object to be shaped is not adjacent to a first partial shaped object that is shaped previously and is shaped with a gap between the first partial shaped object and the second partial shaped object, the second partial shaped object is shaped by setting the discharged shaping amount to a first discharged shaping amount, and in a case in which the second partial shaped object is adjacent to the first partial shaped object, the second partial shaped object is shaped by setting the discharged shaping amount to a second discharged shaping amount that is greater than the first discharged shaping amount.

In a method for manufacturing a three-dimensional shaped object, when an amount of a shaping material discharged toward a shaping surface per unit movement amount of a discharging unit is defined as a discharged shaping amount, in a layer forming step of forming a layer on the shaping surface, in a case in which a second partial shaped object to be shaped is not adjacent to a first partial shaped object that is shaped previously and is shaped with a gap between the first partial shaped object and the second partial shaped object, the second partial shaped object is shaped by setting the discharged shaping amount to a first discharged shaping amount, and in a case in which the second partial shaped object is adjacent to the first partial shaped object, the second partial shaped object is shaped by setting the discharged shaping amount to a second discharged shaping amount that is greater than the first discharged shaping amount.

Provided is a print head, a system and method for pressure measurements and continuous control of a flowable material in a flow path. The system includes a pressure coupler comprising a body having a channel through the longitudinal center of the body, the channel spanning between a first opening and a second opening. The pressure coupler includes a membrane embedded in the body, wherein the membrane is contiguous with, and forms a region of, the channel. Material flowing through the channel imparts a force on the membrane, and the force is transferred from the membrane to a pressure sensor adjacent to the pressure coupler. The pressure coupler and sensor may be included in a print head, whereby the pressure of a flowable material is measured during dispensing from the print head. The pressure measurements are used for continuous feedback flow control of the flowable material through the flow path.

Provided is a print head, a system and method for pressure measurements and continuous control of a flowable material in a flow path. The system includes a pressure coupler comprising a body having a channel through the longitudinal center of the body, the channel spanning between a first opening and a second opening. The pressure coupler includes a membrane embedded in the body, wherein the membrane is contiguous with, and forms a region of, the channel. Material flowing through the channel imparts a force on the membrane, and the force is transferred from the membrane to a pressure sensor adjacent to the pressure coupler. The pressure coupler and sensor may be included in a print head, whereby the pressure of a flowable material is measured during dispensing from the print head. The pressure measurements are used for continuous feedback flow control of the flowable material through the flow path.