A method aspect of the present invention for preparing a continuous thermoplastic filament having a plurality of segments is provided. The method may comprise supplying thermoplastic filaments, and may comprise guiding the thermoplastic filaments alternatingly and sequentially into position to be cut, with respective filament guide components. The method may further comprise cutting each of the thermoplastic filaments into segments by a filament cutting component. Each of the segments may have a forward end and a trailing end. The method may yet further comprise guiding and aligning the forward end of one segment into contact with the trailing end of another segment. The method may also include heating and joining the forward end of the one segment to the trailing end of the other segment to form the continuous thermoplastic filament.

A material deposition system for additive manufacturing including an extruder that defines a first input passage for supplying a first material, a second input passage for supplying a second material, a chamber for combining the first and second materials to form a combined deposition material, and an extrusion port for extruding the combined deposition material. The system further includes an adjustable sleeve that is movable between a first position and a second position to vary the interaction between the first material and the second material in the chamber. For example, the adjustable sleeve may be configured to separate the first and second materials in the chamber, and can vary the point at which the materials interface with each other prior to deposition based on the sleeve position. Such a system may enable a varying degree of infiltration, encapsulation, or other interaction between the first and second materials prior to deposition.

A printer system may include a coaxial extruder head that extrudes a core, a bulk, and/or a core and bulk cladding to form complex structures without retooling. The coaxial extruder head may include a distribution channel with an entrance and an exit, a priming chamber that surrounds the distribution channel. The priming chamber may include an outlet and a first inlet, a heating element thermally connected to the priming chamber, and a nozzle connected to the outlet of the priming chamber. Further, the nozzle may converge from the outlet of the priming chamber to an orifice of the nozzle. In addition, the exit of the distribution channel may be disposed at the orifice of the nozzle. This structure facilitates extruding a core and cladding type composite from the extruder head.

A printer system may include a coaxial extruder head that extrudes a core, a bulk, and/or a core and bulk cladding to form complex structures without retooling. The coaxial extruder head may include a distribution channel with an entrance and an exit, a priming chamber that surrounds the distribution channel. The priming chamber may include an outlet and a first inlet, a heating element thermally connected to the priming chamber, and a nozzle connected to the outlet of the priming chamber. Further, the nozzle may converge from the outlet of the priming chamber to an orifice of the nozzle. In addition, the exit of the distribution channel may be disposed at the orifice of the nozzle. This structure facilitates extruding a core and cladding type composite from the extruder head.

An extruding process and assembly for creating a structural form, which includes the steps of bundling and conveying at least one length of a material into an extruder, reshaping a cross section of the bundle in a first stage of the extruder, extruding a material using any combination of heat and pressure around and between the lengths of material, and outputting a finished article having a cross sectional profile in which the materials are structurally supported by the extruded and hardened material. Other steps include an intermediate chilling stage between reshaping and extruding, and for preventing the extruded material from back flowing. The extruded material further includes any of a polymeric or structural foam material and can exhibit any of a rounded, square, rectangular or I beam cross sectional profile.

An extrusion head arrangement has a plurality of extrusion heads arranged next to one another along a transverse axis. Each extrusion head has a housing with at least one flow channel for forming a strand of extrudable plastic in the direction of a longitudinal axis. The housing has an outer housing part extending along the longitudinal axis with an outer circumferential surface. A longitudinal bore parallel to the longitudinal axis is arranged in the outer housing part. The outer circumferential surface of the outer housing part has an oval cross-section with a largest diameter and a smallest diameter. The extrusion heads are arranged next to each other with the smallest diameters parallel to the transverse axis. The longitudinal bores are each arranged on a diameter deviating from the smallest diameter.

Embodiments of the invention are directed to methods, devices, and compositions for 3D printing of piezoelectric devices. The piezoelectric devices can be used for sensor applications using poly(vinylidene) fluoride (PVDF) and BaTiO.sub.3 (BTO) nanocomposites through in-situ electric poling 3D printing process.

The invention provides a rapid prototyping device and method thereof. The rapid prototyping device comprises an environmental temperature sensor, a control module, a nozzle, and a heating device. The rapid prototyping method comprises following steps of: sensing an environmental temperature, acquiring a nozzle heating temperature according to the environmental temperature; and heating a nozzle till reaching the nozzle heating temperature. After the preparation of the rapid prototyping device, the environmental temperature sensor senses an environmental temperature, then the control module acquires a nozzle heating temperature based on the environmental temperature, and then the control module controls the heating device for heating the nozzle to the nozzle heating temperature. By the temperature compensating function of the present invention, the quality of the heating material ejected by the nozzle can be maintained.

Apparatus, systems, and methods that ultrasonically agitate a semisolid metal slurry to prevent dendrite formation that can lead to clogging of a nozzle during direct metal writing.

Silicone-containing light fixture optics. A method for manufacturing an optical component may include mixing two precursors of silicone, opening a first gate of an optic forming device, moving the silicone mixture from the extrusion machine into the optic forming device, cooling the silicone mixture as it enters the optic forming device, filling a mold within the optic forming device with the silicone mixture, closing the first gate, and heating the silicone mixture in the mold to at least partially cure the silicone. Alternatively, a method for manufacturing an optical component may include depositing a layer of heat cured silicone optical material to an optical structure, arranging one or more at least partially cured silicone optics on the layer of heat cured silicone optical material, and heating the heat cured silicone optical material to permanently adhere the one or more at least partially cured silicone optics to the optical structure.