A 3-D printer includes a development station positioned to electrostatically transfer layers of material to an intermediate transfer surface, and a transfuse station adjacent the intermediate transfer surface. The transfuse station is positioned to receive the layers as the intermediate transfer surface moves past the transfuse station. Also, a platen is included that moves relative to the intermediate transfer surface. The intermediate transfer surface transfers a layer of the material to the platen each time the platen contacts one of the layers on the intermediate transfer surface at the transfuse station to successively form a freestanding stack of the layers on the platen. A curing station is positioned to apply ultraviolet light to each layer, after each layer is transferred from the transfuse station to the platen. The curing station selectively applies the ultraviolet light to crosslink polymers only in a portion of the material within the layer.

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.

A method for additive production of a component, which includes the additive construction of the component on a component platform having an opening, wherein, during the first part of the additive construction of the component an auxiliary structure is produced additively around the opening of the component platform. The method further includes the introduction of a device through the opening into a cavity defined by the auxiliary structure, wherein, during a second part of the additive construction, following the first part of the additive construction, properties of the component to be produced are influenced and/or measured by the device. A component is produced by the method and an apparatus for the additive production of the component, includes the component platform having the opening and the closure.

A method for additive production of a component, which includes the additive construction of the component on a component platform having an opening, wherein, during the first part of the additive construction of the component an auxiliary structure is produced additively around the opening of the component platform. The method further includes the introduction of a device through the opening into a cavity defined by the auxiliary structure, wherein, during a second part of the additive construction, following the first part of the additive construction, properties of the component to be produced are influenced and/or measured by the device. A component is produced by the method and an apparatus for the additive production of the component, includes the component platform having the opening and the closure.

A 3D printer head comprises a chamber that is configured for receiving liquid or solid print material through an inlet. The chamber has an outlet opening on one surface, and a spiral feed screw is associated with the chamber and is configured for supplying the outlet opening with print material that passes from the inlet into the chamber, by coupling the spiral feed screw or the chamber to a drive that is configured for rotating the spiral feed screw or the chamber in such a way that the spiral feed screw rotates at a distance from the surface of the chamber and relative thereto. The spiral feed screw has at least one conveyor that is configured for conveying print material between a radially outwardly situated inlet area and a radially inwardly situated outlet area, toward the latter, and at least one discharge conveyor that is arranged and configured for conveying print material, together with gas present therein, away from at least one section of a radially outer border zone of the outlet area.

A 3D printer head comprises a chamber that is configured for receiving liquid or solid print material through an inlet. The chamber has an outlet opening on one surface, and a spiral feed screw is associated with the chamber and is configured for supplying the outlet opening with print material that passes from the inlet into the chamber, by coupling the spiral feed screw or the chamber to a drive that is configured for rotating the spiral feed screw or the chamber in such a way that the spiral feed screw rotates at a distance from the surface of the chamber and relative thereto. The spiral feed screw has at least one conveyor that is configured for conveying print material between a radially outwardly situated inlet area and a radially inwardly situated outlet area, toward the latter, and at least one discharge conveyor that is arranged and configured for conveying print material, together with gas present therein, away from at least one section of a radially outer border zone of the outlet area.

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.

Systems and methods are provided for incremental 3D printing, wherein wireframes are generated and printed (scheduled for print) during the design process. In another aspect, systems and methods are provided for printing arbitrary meshes. A 3D printer system is described having, for example, five degree-of-freedom (5DOF). The 5DOF printer may be used to perform any of the methods described herein and combinations of the methods.

Systems and methods are provided for incremental 3D printing, wherein wireframes are generated and printed (scheduled for print) during the design process. In another aspect, systems and methods are provided for printing arbitrary meshes. A 3D printer system is described having, for example, five degree-of-freedom (5DOF). The 5DOF printer may be used to perform any of the methods described herein and combinations of the methods.