Described herein are methods and compositions for forming three-dimensional objects via material jetting processes, the methods including the repeated steps of selectively depositing a liquid thermoset material onto a surface from a nozzle of at least one jetting head in a first specified direction and exposing at least a portion of the liquid thermoset material to a source of actinic radiation in order to form a three-dimensional object from the cured thermoset material, wherein the jetting head is configured to eject droplets of the liquid thermoset material from the nozzle at prescribed elevated operating temperatures, and wherein the liquid thermoset material is chosen so as to possessing prescribed viscosity and rheological characteristics.

The present application provides a 3D printing method. The present application can provide as a method for efficiently performing 3D printing, for example, a 3D printing method capable of more rapidly and efficiently producing a three-dimensional shape precisely realized up to a fine portion.

The present application provides a 3D printing method. The present application can provide as a method for efficiently performing 3D printing, for example, a 3D printing method capable of more rapidly and efficiently producing a three-dimensional shape precisely realized up to a fine portion.

An additive layer manufacturing method, preferably using selective laser sintering, for manufacturing a solid article, the method including applying a layer of a powder, the powder including at least one powdered (co)polymer, onto a solid substrate in a processing chamber; fusing the powder layer onto the solid substrate; subsequently depositing successive layers of the powder, wherein each successive layer is selectively fused prior to deposition of the subsequent layer of powder so as to form the article. In some embodiments, the powder further includes abrasive particles having a hardness greater than or equal to that of aluminum oxide.

An additive layer manufacturing method, preferably using selective laser sintering, for manufacturing a solid article, the method including applying a layer of a powder, the powder including at least one powdered (co)polymer, onto a solid substrate in a processing chamber; fusing the powder layer onto the solid substrate; subsequently depositing successive layers of the powder, wherein each successive layer is selectively fused prior to deposition of the subsequent layer of powder so as to form the article. In some embodiments, the powder further includes abrasive particles having a hardness greater than or equal to that of aluminum oxide.

Disclosed are systems, devices, and methods for additive manufacturing that allow for control of composition and/or porosity of components being manufactured. More particularly, in exemplary embodiments, a secondary material can be used in conjunction with a primary feedstock material in a spatially controlled manner during an additive manufacturing process to control a composition of materials and/or porosity of a manufactured component. Systems, devices, and methods for additive manufacturing are also disclosed that allow for control of a pressure of an atmosphere surrounding a build surface during an additive manufacturing process. More particularly, a pressure of an atmosphere surrounding a build surface can be raised to a pressure greater than standard atmospheric pressure. Various features of the exemplary embodiments of the systems, devices, and methods disclosed can be used together to further control for composition and/or porosity and quality of a manufactured part.

A system is disclosed for use in additively manufacturing a structure. The system may include an additive manufacturing machine, a memory having computer-executable instructions stored thereon, and a processor. The processor may be configured to execute the computer-executable instructions to determine a plurality of tension vectors to be generated within the structure, and to generate a plan for manufacturing the structure. The plan may include tool paths that arrange continuous fibers within the structure to generate the plurality of tension vectors. The processor may also be configured to execute the computer-executable instructions to cause the additive manufacturing machine to follow the plan and manufacture the structure.

Porous and microporous parts prepared by additive manufacturing as disclosed herein are useful in medical and non-medical applications. The parts are prepared from a composition containing both a solvent soluble component and a solvent insoluble component. After a part is printed by an additive manufacturing process it is exposed to solvent to extract solvent soluble component away from the printed part, resulting in a part having surface cavities.

Porous and microporous parts prepared by additive manufacturing as disclosed herein are useful in medical and non-medical applications. The parts are prepared from a composition containing both a solvent soluble component and a solvent insoluble component. After a part is printed by an additive manufacturing process it is exposed to solvent to extract solvent soluble component away from the printed part, resulting in a part having surface cavities.

Ceramic slurries may include ceramic particles, a photoreactive-photostable hybrid binder, and a photoinitiator. The photoreactive-photostable hybrid binder may include a photoreactive organic resin component, a photoreactive siloxane component, and one or more photostable siloxane components. Methods of forming a ceramic part may include curing a portion of a ceramic slurry by exposing the portion of the ceramic slurry to light to form a green ceramic part, and partially firing the green ceramic part to form a brown ceramic part. The brown ceramic part may be sintered at or above a sintering temperature of the ceramic particles to form a ceramic part, wherein sintering includes heating the brown ceramic part to a sufficient temperature to promote reaction bonding that converts silica from the photoreactive-photostable hybrid binder into silicates that bond with the ceramic particles.