Methods to fabricate objects by 3D printing of poly-4-hydroxybutyrate (P4HB) and copolymers thereof have been developed. In one method, these objects are produced by continuous fused filament fabrication using an apparatus and conditions that overcome the problems of poor feeding of the filament resulting from the low softening temperature of the filament and heat creep along the fed filament. Methods using an apparatus including a heat sink, a melt tube, a heating block and nozzle, and a transition zone between the heat sink and heating block, with the melt tube extending through the heat sink, transition zone, and heat block to the nozzle are disclosed. 3D objects are also printed by fused pellet deposition (FPD), melt extrusion deposition (MED), selective laser melting (SLM), printing of slurries and solutions using a coagulation bath, and printing using a binding solution and polymer granules.

Methods to fabricate objects by 3D printing of poly-4-hydroxybutyrate (P4HB) and copolymers thereof have been developed. In one method, these objects are produced by continuous fused filament fabrication using an apparatus and conditions that overcome the problems of poor feeding of the filament resulting from the low softening temperature of the filament and heat creep along the fed filament. Methods using an apparatus including a heat sink, a melt tube, a heating block and nozzle, and a transition zone between the heat sink and heating block, with the melt tube extending through the heat sink, transition zone, and heat block to the nozzle are disclosed. 3D objects are also printed by fused pellet deposition (FPD), melt extrusion deposition (MED), selective laser melting (SLM), printing of slurries and solutions using a coagulation bath, and printing using a binding solution and polymer granules.

An example technique includes extruding, by a tow deposition device, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a layer of material on a major surface of a substrate. Each respective impregnated tow includes at least one ceramic fiber and a curable resin coating the at least one ceramic fiber. The example technique includes curing the curable resin to form a cured composite component. An example system includes a tow deposition device, an energy source, and a computing device. The computing device is configured to control the tow deposition device to extrude, on a tow-by-tow basis, respective impregnated tows of a plurality of respective impregnated tows to form a layer of material, and is configured to control the energy source to cure the curable resin to form a cured composite component.

In an inflatable structure, a plurality of fibers is formed in a cavity of a flexible shell. When structure is inflated, the shell expands and the fibers are tensioned to constrain the flexible shell to have a fiber-constrained shape. When the structure is uninflated, the flexible shell is configured to collapse. The structure is formed by additive manufacturing. The fibers are fused to the shell and can run in various directions in relation to each other and the flexible shell. Fibers can extend obliquely to the shell when tensioned and at crosswise directions in relation to each other to form a nonwoven mesh.

In an inflatable structure, a plurality of fibers is formed in a cavity of a flexible shell. When structure is inflated, the shell expands and the fibers are tensioned to constrain the flexible shell to have a fiber-constrained shape. When the structure is uninflated, the flexible shell is configured to collapse. The structure is formed by additive manufacturing. The fibers are fused to the shell and can run in various directions in relation to each other and the flexible shell. Fibers can extend obliquely to the shell when tensioned and at crosswise directions in relation to each other to form a nonwoven mesh.

Rapid prototyping and delivery of fluorescent medical devices using a 3D printer provided with a processed digital design and fluorescent filament feedstock. The fluorescent filament may comprise a polymer such as acrylonitrile butadiene styrene and between 10 and 100 ppm of a fluorophore such as indocyanine green embedded uniformly throughout the polymer. The filament may include about one percent by weight of a colorant. The 3D printer may be located at the site of use by an end user, such as a physician office, hospital, or operating room for printing of the fluorescent medical device on demand.

A system and method for three-dimensionally printing high viscosity materials using electrohydrodynamics is provided. The system uses a relatively low voltage electric field to draw high viscosity polymers (not in solution) from a nozzle to form three-dimensional objects with lines less than 10 microns in width. Pressurized gas at the nozzle outlet can be used to print large size/dimension parts, instead of or in addition to the electric field to draw the polymers from the nozzle.

A system and method for three-dimensionally printing high viscosity materials using electrohydrodynamics is provided. The system uses a relatively low voltage electric field to draw high viscosity polymers (not in solution) from a nozzle to form three-dimensional objects with lines less than 10 microns in width. Pressurized gas at the nozzle outlet can be used to print large size/dimension parts, instead of or in addition to the electric field to draw the polymers from the nozzle.

A method and apparatus are provided for producing a multicomponent feedstock being delivered through a print head of a 3D printer. Multiple component lengths are produced from separate feedstocks and are aligned to form the multicomponent feedstock which is fed into the print head for extrusion. The method includes providing at least two sources of feedstock of different material, feeding a distal end of a first feedstock along a feed path, cutting the first feedstock at a pre-determined length to provide a length of first feedstock having a proximal end. The method includes feeding a distal end of a second feedstock along the feed path and aligning the distal end of the second feedstock with the proximal end of the length of the first feedstock. The second feedstock is cut at a pre-determined length to provide a length of the second feedstock serially aligned with the length of first feedstock, to form a length of multicomponent feedstock. The length of multicomponent feedstock is fed into the print head.

A method and apparatus are provided for producing a multicomponent feedstock being delivered through a print head of a 3D printer. Multiple component lengths are produced from separate feedstocks and are aligned to form the multicomponent feedstock which is fed into the print head for extrusion. The method includes providing at least two sources of feedstock of different material, feeding a distal end of a first feedstock along a feed path, cutting the first feedstock at a pre-determined length to provide a length of first feedstock having a proximal end. The method includes feeding a distal end of a second feedstock along the feed path and aligning the distal end of the second feedstock with the proximal end of the length of the first feedstock. The second feedstock is cut at a pre-determined length to provide a length of the second feedstock serially aligned with the length of first feedstock, to form a length of multicomponent feedstock. The length of multicomponent feedstock is fed into the print head.