Apparatus and methods for additive manufacturing at ambient temperature

An additive manufacturing system, comprising:

• a carrier;
• an extruder having an opening dimensioned to receive a material, a barrel, and a screw positioned within the barrel, wherein the barrel extends along a longitudinal axis, wherein the extruder is coupled to the carrier;
• one or more heaters positioned along at least a portion of the barrel, wherein, as the material passes through the barrel, the one or more heaters at least partially melt the material;
• a gear pump in fluid communication with the barrel for receiving the at least partially melted material;
• a nozzle in fluid communication with the gear pump for depositing the at least partially melted material, wherein the nozzle has a diameter ranging between about 0.2 inches to about 1.0 inches;
• a cooling mechanism including at least one of a fan, a blower, coolant, or an air conditioner configured to cool layers of the at least partially melted material supported on a base layer of the at least partially melted material to an at least partially solid state in a layer by layer manner;
• and
• a vertical worktable including a planar side surface configured to support the base layer deposited thereon, the at least partially melted material being deposited in an environment having a temperature of 65-85 degrees Fahrenheit.

An additive manufacturing system, comprising:

• an extruder having an opening dimensioned to receive a material, a barrel extending along a longitudinal axis, and a screw, wherein the extruder has a throughput rate ranging from about 110 pounds of material per hour to about 500 pounds of material per hour, wherein the extruder is movable along a plurality of axes;
• one or more heaters positioned along at least a portion of the barrel, wherein, as the material passes through the barrel, the one or more heaters at least partially melt the material;
• a gear pump in fluid communication with the barrel for receiving the at least partially melted material;
• a nozzle in fluid communication with the gear pump for depositing the at least partially melted material;
• at least one cooling mechanism including a fan, a blower, coolant, or an air conditioner configured to cool layers of the at least partially melted material supported on a base layer of the at least partially melted material to an at least partially solid state in a layer by layer manner;
• and
• a vertical worktable including a planar side surface configured to support the base layer deposited thereon, the at least partially melted material being deposited in an environment having a temperature of 65-85 degrees Fahrenheit.