Embodiments herein relate to 3D printing. In an embodiment, a method for printing an article using a selective toner electrophotographic process (“STEP”) includes successively depositing multiple layers of part material, the layers deposited substantially parallel to a first plane; wherein: a) the multiple areas of part material extend in a perpendicular to the first plane; and b) at least some of the areas of part material are separated from each other to form a gap between the layers of part material; application of heat and pressure to the part material such that a portion of the part material flows into and at least partially fills the gap within the part material.
B29C 64/141 - Processes of additive manufacturing using only solid materials
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
B29K 55/02 - ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
A system and method for printing a 3D part is disclosed. The method includes forming a material toner image on a transfer medium including a registration pattern comprising at least three features (the features combined to form a fiducial); transporting the material toner image on the transfer medium to a sensor such that the features may be detected by the sensor; storing a position measurement for each feature detected by the sensor; calculating a score for subsets of features with reference to a template; adjusting the relative position of the transfer medium and a build surface based on at least the positions of the selected features; and transferring the toner image from the transfer medium to the build surface.
The present disclosure is directed to a method for selective thermoplastic electrophotographic process additive manufacturing. In particular, this disclosure is directed to measuring the height of the build (the deposited part material and support material) against a reference (desired) height and making adjustments in subsequent deposited layers to correct any deficiencies in the build.
The present disclosure is directed to a support composition for additive manufacturing, the support composition comprising a soluble support polymer and a finely divided particulate, In certain embodiments the particulate is about 5% by weight to 25% by weight of the support composition. In certain embodiments the particulate is at or below 1 μm weight average particle size.
The present disclosure is directed, in part, to method for selective thermoplastic electrophotographic process additive manufacturing, the method comprising applying a high-absorbance support material and a low-absorbance part material adjacent to one another: applying radiated energy to the high-absorbance support material and low-absorbance part material such that the high-absorbance support material selectively absorbs the radiated energy and transfers heat to the low-absorbance part material.
Embodiments herein relate to 3D printing. In an embodiment, a method for printing an article using a selective toner electrophotographic process (“STEP”) includes successively depositing multiple layers of part material and support material, the layers deposited substantially parallel to a first plane: wherein: a) the multiple layers of part material and support material extend in a perpendicular to the first plane; and b) at least some of the layers of part material and support material are separated from each other to form a gap between the layers of part material and layers of support material: application of heat and pressure to the part material and support material such that a portion of the part material and support material flows into and at least partially fills the gap between the part material and support material.
B29C 64/141 - Processes of additive manufacturing using only solid materials
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
Systems and methods for controlling the transfusion pressure in an additive manufacturing system are described. The system has a layer transfusion assembly that can include a build platform. The layer transfusion assembly is configured to transfuse the layers at a transfusion pressure in a layer-by-layer manner onto the build platform to print a three-dimensional part, and a controller is configured to set the transfusion pressure, wherein the transfusion pressure can vary along the x-direction of the build platform in a controlled manner.
An additive printing composition, the additive printing composition comprising a nylon toner and a magnetic carrier; wherein the magnetic carrier comprises less than 1.0 percent of a polymeric coating. Optionally the magnetic carrier is coated with less than 0.75% of a polymeric coating, less than 0.5% of a polymeric coating, or less than 0.3% of a polymeric coating.
A method of producing a part using a selective toner electrophotographic process, the method comprising: providing a build surface; depositing layers of support material onto the build surface; building up a part by depositing layers of part material onto the support surface to reach a part top surface; and adding a plurality of layers of support material to the top of the part material above the part top surface.
Methods and systems for additive manufacturing are disclosed, the methods and systems comprising reducing the amount of support material used, by one or more methods, including inclusion of part material voxels and air voxels within the support regions, using a lattice of part material within support regions, printing one or more skin layers and boundary layers to support the part geometry and surface, and printing support layers in a drafted manner to reduce support material.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
B29C 64/223 - Foils or films, e.g. for transferring layers of building material from one working station to another
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
11.
ADDITIVE MANUFACTURING SYSTEM AND METHOD WITH SMOOTH SURFACE
Embodiments herein relate to 3D printing. In an embodiment, a method for printing an article using a selective toner electrophotographic process ("STEP") includes successively depositing multiple layers of part material and support material, the layers deposited substantially parallel to a first plane; wherein: a) the multiple layers of part material and support material extend in a perpendicular to the first plane; and b) at least some of the layers of part material and support material are separated from each other to form a gap between the layers of part material and layers of support material; application of heat and pressure to the part material and support material such that a portion of the part material and support material flows into and at least partially fills the gap between the part material and support material.
The present disclosure is directed to a support composition for additive manufacturing, the support composition comprising a soluble support polymer and a finely divided particulate, In certain embodiments the particulate is about 5 % by weight to 25% by weight of the support composition. In certain embodiments the particulate is at or below 1 µm weight average particle size.
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
The present disclosure is directed to a method for selective thermoplastic electrophotographic process additive manufacturing. In particular, this disclosure is directed to measuring the height of the build (the deposited part material and support material) against a reference (desired) height and making adjustments in subsequent deposited layers to correct any deficiencies in the build.
The present disclosure is directed, in part, to method for selective thermoplastic electrophotographic process additive manufacturing, the method comprising applying a high- absorbance support material and a low-absorbance part material adjacent to one another; applying radiated energy to the high-absorbance support material and low-absorbance part material such that the high-absorbance support material selectively absorbs the radiated energy and transfers heat to the low-absorbance part material.
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
Systems and methods for controlling the transfusion pressure in an additive manufacturing system are described. The system has a layer transfusion assembly that can include a build platform. The layer transfusion assembly is configured to transfuse the layers at a transfusion pressure in a layer-by-layer manner onto the build platform to print a three-dimensional part, and a controller is configured to set the transfusion pressure, wherein the transfusion pressure can vary along the x-direction of the build platform in a controlled manner.
Embodiments herein relate to 3D printing. In an embodiment, a method for printing an article using a selective toner electrophotographic process ("STEP") includes successively depositing multiple layers of part material, the layers deposited substantially parallel to a first plane; wherein: a) the multiple areas of part material extend in a perpendicular to the first plane; and b) at least some of the areas of part material are separated from each other to form a gap between the layers of part material; application of heat and pressure to the part material such that a portion of the part material flows into and at least partially fills the gap within the part material.
A cooling assembly, and method, for an article being printed using a selective toner electrophotographic printing system is disclosed. The assembly includes a surface for delivering and returning cooling gas, the surface containing first plurality of elongate openings in communication with a cooling gas supply; and a second plurality elongate openings in communication with a cooling gas return; wherein the first plurality of elongate openings and second plurality of elongate openings are substantially parallel to one another and alternate with one another.
A part material for printing three-dimensional parts with a selective deposition-based additive manufacturing system has a composition having a thermoplastic elastomer (TPE) polymer and a surface modifier. The TPE polymer is polyether block amide (PEBA). The part material is provided in a powder form having a D90/D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 2.0, wherein the part material is configured for use in the selective deposition-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
Disclosed are selective layer deposition based additive manufacturing systems and methods for printing a 3D part. Layers of a powder material are developed using one or more electrostatography-based engines. The layers are transferred for deposition on a part build surface. One or more lasers are used to heat a region of the part build surface and a developed layer near the nip roller entrance. The developed layer is then pressed into the part build surface.
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
In a method of printing a 3D part in accordance with a selective deposition additive manufacturing process a first image portion of a flowable material is developed using a first electrophotographic engine. A second image portion of a resilient material is developed using a second electrophotographic engine. The first image portion is registered with respect to the second image portion to form a combined image layer comprising the first and second image portions on a transfer medium. The combined image layer is transfused from the transfer medium to a part build surface of a 3D part. The viscosity (Vr) of the resilient material is greater than or equal to three times the viscosity (Vf) of the flowable material, and/or the storage modulus (Er) of the resilient material is greater than or equal to three times the storage modulus (Ef) of the flowable material.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
Embodiments herein relate to 3D printing. In an embodiment, a method for printing an article using a selective toner electrophotographic process (“STEP”) includes successively depositing multiple layers of part material and support material, the layers deposited substantially parallel to a first plane; wherein: a) the multiple layers of part material and support material extend in a perpendicular to the first plane; and b) at least some of the layers of part material and support material are separated from each other to form a gap between the layers of part material and layers of support material; application of heat and pressure to the part material and support material such that a portion of the part material and support material flows into and at least partially fills the gap between the part material and support material.
G03G 15/00 - Apparatus for electrographic processes using a charge pattern
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
G03G 15/20 - Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/34 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups in which the powder image is formed directly on the recording material
22.
Layer transfusion sequencing for selective deposition-based additive manufacturing
A method for making a three-dimensional (3D) part with an electrostatographic based additive manufacturing system includes establishing first and second control parameter profiles, establishing a transfusion sequence, and transfusing n+m layers on a bonding region of previously accumulated layers of the 3D part according to the transfusion sequence. The first and second control parameter profiles each include a different combination of temperature and pressure parameters usable to transfuse a single layer of the 3D part. The transfusion sequence specifies the use of each of the first and second control parameter profiles in a specified order. A total thickness of the n+m layers is less than a thermal diffusion depth. The transfusion step includes transfusing n layers according to the first control parameter profile, and, after transfusing then layers, transfusing m layers according to the second control parameter profile.
B29C 64/141 - Processes of additive manufacturing using only solid materials
B29C 64/176 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects sequentially
B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
A selective deposition-based additive manufacturing system capable of building a three-dimensional (3D) part utilizing a semi-crystalline polymeric material includes at least one electrostatographic engine configured to develop one or more layers of particles of semi-crystalline polymeric material corresponding to one or more slices of a 3D model of a 3D part. The system includes a transfer medium configured to receive the one or more layers of particles of the semi-crystalline polymeric material on a front side from the at least one electrostatographic engine and to move the one or more layers away from the electrostatographic engine and a platen configured to carry the 3D part or support being printed. The system includes a gantry coupled to the platen and configured to move the platen into registration with the one or more layers, and a heater configured to heat a top surface of the 3D part being printed to a transfuse temperature. The system includes a layer transfer assembly having a roller contacting a back side of the transfer medium and a driver configured to cause the layer to transfer from the front side of the transfer medium to the heated top surface of the part. The system includes a cooler configured to cool the heated semi-crystalline polymeric material at a maximum rate of at least 20° C. per second such that the semi-crystalline material is in a super-cooled state wherein the semi-crystalline polymeric material does not completely initially crystallize.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
An apparatus for use in a selective toner electrophotographic process (STEP) additive manufacturing system, the apparatus includes a radiant heat source configured to emit radiation of a first band of wavelengths in the region of a transfuse roller nip; and a pyrometer configured to receive and measure radiation emitted from the region of the transfuse roller nip; wherein the radiation measured by the pyrometer comprises a second band of wavelengths different from the first band of wavelengths emitted by the radiant heat source. The radiant heat source is typically one or more laser light emitters.
B29C 64/386 - Data acquisition or data processing for additive manufacturing
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
B29C 64/282 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
G03G 15/20 - Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat
25.
ADDITIVE MANUFACTURING METHODS USING REDUCED SUPPORT MATERIAL
Methods and systems for additive manufacturing are disclosed, the methods and systems comprising reducing the amount of support material used, by one or more methods, including inclusion of part material voxels and air voxels within the support regions, using a lattice of part material within support regions, printing one or more skin layers and boundary layers to support the part geometry and surface, and printing support layers in a drafted manner to reduce support material.
A cooling assembly, and method, for an article being printed using a selective toner electrophotographic printing system is disclosed. The assembly includes a surface for delivering and returning cooling gas, the surface containing first plurality of elongate openings in communication with a cooling gas supply; and a second plurality elongate openings in communication with a cooling gas return; wherein the first plurality of elongate openings and second plurality of elongate openings are substantially parallel to one another and alternate with one another.
Embodiments herein relate to 3D printing. In an embodiment, a method for printing an article using a selective toner electrophotographic process ("STEP") includes successively depositing multiple layers of part material and support material, the layers deposited substantially parallel to a first plane; wherein: a) the multiple layers of part material and support material extend in a perpendicular to the first plane; and b) at least some of the layers of part material and support material are separated from each other to form a gap between the layers of part material and layers of support material; application of heat and pressure to the part material and support material such that a portion of the part material and support material flows into and at least partially fills the gap between the part material and support material.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
In a method of printing a 3D part in accordance with a selective deposition additive manufacturing process a first image portion of a flowable material is developed using a first electrophotographic engine. A second image portion of a resilient material is developed using a second electrophotographic engine. The first image portion is registered with respect to the second image portion to form a combined image layer comprising the first and second image portions on a transfer medium. The combined image layer is transfused from the transfer medium to a part build surface of a 3D part. The viscosity (Vr) of the resilient material is greater than or equal to three times the viscosity (Vf) of the flowable material, and/or the storage modulus (Er) of the resilient material is greater than or equal to three times the storage modulus (Ef) of the flowable material.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
Disclosed are selective layer deposition based additive manufacturing systems and methods for printing a 3D part. Layers of a powder material are developed using one or more electrostatography-based engines. The layers are transferred for deposition on a part build surface. One or more lasers are used to heat a region of the part build surface and a developed layer near the nip roller entrance. The developed layer is then pressed into the part build surface.
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
A part material for printing three-dimensional parts with a selective deposition-based additive manufacturing system has a composition having a thermoplastic elastomer (TPE) polymer and a surface modifier. The TPE polymer is polyether block amide (PEBA). The part material is provided in a powder form having a D90/D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 2.0, wherein the part material is configured for use in the selective deposition-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
C08L 77/00 - Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chainCompositions of derivatives of such polymers
A selective deposition-based additive manufacturing system capable of building a three-dimensional (3D) part utilizing a semi-crystalline polymeric material includes at least one electrostatographic engine configured to develop one or more layers of particles of semi-crystalline polymeric material corresponding to one or more slices of a 3D model of a 3D part. The system includes a transfer medium configured to receive the one or more layers of particles of the semi-crystalline polymeric material on a front side from the at least one electrostatographic engine and to move the one or more layers away from the electrostatographic engine and a platen configured to carry the 3D part or support being printed. The system includes a gantry coupled to the platen and configured to move the platen into registration with the one or more layers, and a heater configured to heat a top surface of the 3D part being printed to a transfuse temperature. The system includes a layer transfer assembly having a roller contacting a back side of the transfer medium and a driver configured to cause the layer to transfer from the front side of the transfer medium to the heated top surface of the part. The system includes a cooler configured to cool the heated semi-crystalline polymeric material at a maximum rate of at least 20ºC per second such that the semi-crystalline material is in a super-cooled state wherein the semi-crystalline polymeric material does not completely initially crystallize.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
B29C 64/223 - Foils or films, e.g. for transferring layers of building material from one working station to another
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/176 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects sequentially
B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
d). The layers (22) are transferred for deposition on a part build surface (88). For each of the layers (22), the part build surface (88) is pre-heated by impinging a first heat transfer liquid (74) toward the part build surface (88), for example using a solder fountain. The developed layer (22) is pressed into contact with the heated part build surface (88) to heat the developed layer (22) to a flowable state and form a new part build surface (88) which is fully consolidated. The new part build surface (88) is then rapidly cooled to remove the heat energy added during heating step before repeating the steps for the next developed layer (22).
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Disclosed are selective deposition based additive manufacturing systems (10) and methods for printing a 3D part. Layers of a powder material (22) are developed using one or more electrostatography-based engines (12). The layers (22) are transferred for deposition on a part build surface. For each of the layers (22), the part build surface is heated to a temperature within a range between a flowable temperature and a thermal oxidation threshold to form a flowable part build surface, and the developed layer (22) is pressed into contact with the flowable build surface (88) to heat the developed layers (22) to a flowable state and form a new part build surface (88) which is fully consolidated. The new part build surface (88) is then cooled to remove the heat energy added during heating step before repeating the steps for the next developed layer.
G03G 15/00 - Apparatus for electrographic processes using a charge pattern
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
A method of selective deposition-based additive manufacturing includes conveying a layer (28) of material to previously built layers (22) of material. A determination is made as to whether at least one of the conveyed layers (28) of material and a top previously built layer (22) of material contains an unsupported portion (302). When at least one of the conveyed layer (28) of material and the top previously built layer (22) of material contains an unsupported portion, a first set of steps (306, 408, 506) are used to transfer the conveyed layer (28) of material to the top previously built layer (22) of material. When neither of the conveyed layer (28) of material and the top previously built layer (22) of material contains an unsupported portion, a second set of steps (304, 406, 504) are used to transfer the conveyed layer (28) of material to the top previously built layer (22) of material.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
A method of operating a selective deposition-based additive manufacturing system capable of building a three-dimensional (3D) part includes developing a first layer using at least one electrostatographic engine, conveying the first layer from the at least one EP engine to a transfusion assembly, determining an anticipated transfusion overlay error for the first layer, determining whether the anticipated transfusion overlay error exceeds an overlay error specification, discarding the first layer after determining that the anticipated transfusion overlay error exceeds the overlay error specification, developing a successive layer using the at least one electrostatographic engine, conveying the successive layer from the at least one electrostatographic engine to the transfusion assembly, and transfusing the successive layer on a part build surface using the transfusion assembly to build the 3D part in a layer-by-layer manner on a part build platform.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
An apparatus for use in a selective toner electrophotographic process (STEP) additive manufacturing system, the apparatus includes a radiant heat source configured to emit radiation of a first band of wavelengths in the region of a transfuse roller nip; and a pyrometer configured to receive and measure radiation emitted from the region of the transfuse roller nip; wherein the radiation measured by the pyrometer comprises a second band of wavelengths different from the first band of wavelengths emitted by the radiant heat source. The radiant heat source is typically one or more laser light emitters.
G03G 15/04 - Apparatus for electrographic processes using a charge pattern for exposing, i.e. imagewise exposure by optically projecting the original image on a photoconductive recording material
G03G 15/00 - Apparatus for electrographic processes using a charge pattern
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
38.
Systems and methods for electrophotography-based additive manufacturing of parts utilizing multiple printing paths
An electrostatic-based layer-wise manufacturing system (e.g., 200; 200-1; 250; 282; 300) decouples a layer imaging process from a layer transfusion process. The layer imaging process is performed in a first batch process that is independent from the layer transfusion process that is performed in a second batch process.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
39.
Thermal partitioning in an electrostatographic additive manufacturing system
A method for making a three-dimensional (3D) part with an electrostatographic based additive manufacturing system includes developing a first layer of a powder material using at least one electrostatographic engine, supporting the developed first layer on a transfer medium, adjusting a first layer thermal profile of the developed first layer with a first thermal flux device, adding thermal energy to a part thermal profile that includes a bonding region of previously accumulated layers of the 3D part, transfusing the developed first layer on the bonding region of the previously accumulated layers of the 3D part, and removing thermal energy from the part thermal profile. A transfusion temperature at a start of the transfusing step can be equal to or greater than a transfusion threshold temperature, where the transfusion temperature is an average of the first layer thermal profile and the part thermal profile in the bonding region.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
40.
Transfuse roller tracking in selective layer deposition based additive manufacturing
A method of additive manufacturing utilizing selective layer deposition includes measuring a transfuse force between a transfuse roller and a part build surface. An angular position of the transfuse roller is measured over time. A component of a transfuse force variation that is periodic in a rotational period of the transfuse roller is estimated, and a vertical position between the transfuse roller and the part build surface is adjusted to reduce pressure variations in transfuse roller force on the build part surface.
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
41.
THERMAL PARTITIONING IN AN ELECTROSTATOGRAPHIC ADDITIVE MANUFACTURING SYSTEM
A method for making a three-dimensional (3D) part with an electrostatographic based additive manufacturing system includes developing a first layer of a powder material using at least one electrostatographic engine, supporting the developed first layer on a transfer medium, adjusting a first layer thermal profile of the developed first layer with a first thermal flux device, adding thermal energy to a part thermal profile that includes a bonding region of previously accumulated layers of the 3D part, transfusing the developed first layer on the bonding region of the previously accumulated layers of the 3D part, and removing thermal energy from the part thermal profile. A transfusion temperature at a start of the transfusing step can be equal to or greater than a transfusion threshold temperature, where the transfusion temperature is an average of the first layer thermal profile and the part thermal profile in the bonding region.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
A method of additive manufacturing utilizing selective layer deposition includes measuring a transfuse force between a transfuse roller (120) and a part build surface. An angular position of the transfuse roller (120) is measured over time. A component of a transfuse force variation that is periodic in a rotational period of the transfuse roller (120) is estimated, and a vertical position between the transfuse roller (120) and the part build surface is adjusted to reduce pressure variations in transfuse roller force on the build part surface.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
Disclosed are selective deposition-based additive manufacturing systems (10) and methods for printing a 3D part (26). Layers of a powder material (22) are developed using one or more electrostatographic engines (12a-d). The layers (22) are transferred for deposition on a part build surface (88). For each of the layers (22), the part build surface (88) is pre -heated by impinging a first heat transfer liquid (74) toward the part build surface (88), for example using a solder fountain. The developed layer (22) is pressed into contact with the heated part build surface (88) to heat the developed layer (22) to a flowable state and form a new part build surface (88) which is fully consolidated. The new part build surface (88) is then rapidly cooled to remove the heat energy added during heating step before repeating the steps for the next developed layer (22).
A method of operating a selective deposition-based additive manufacturing system capable of building a three-dimensional (3D) part includes developing a first layer using at least one electrostatographic engine, conveying the first layer from the at least one EP engine to a transfusion assembly, determining an anticipated transfusion overlay error for the first layer, determining whether the anticipated transfusion overlay error exceeds an overlay error specification, discarding the first layer after determining that the anticipated transfusion overlay error exceeds the overlay error specification, developing a successive layer using the at least one electrostatographic engine, conveying the successive layer from the at least one electrostatographic engine to the transfusion assembly, and transfusing the successive layer on a part build surface using the transfusion assembly to build the 3D part in a layer-by-layer manner on a part build platform.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/00 - Apparatus for electrographic processes using a charge pattern
45.
BUILDING LAYERS WITH UNSUPPORTED PORTIONS THROUGH SELECTIVE DEPOSITION-BASED ADDITIVE MANUFACTURING
A method of selective deposition-based additive manufacturing includes conveying a layer (28) of material to previously built layers (22) of material. A determination is made as to whether at least one of the conveyed layers (28) of material and a top previously built layer (22) of material contains an unsupported portion (302). When at least one of the conveyed layer (28) of material and the top previously built layer (22) of material contains an unsupported portion, a first set of steps (306, 408, 506) are used to transfer the conveyed layer (28) of material to the top previously built layer (22) of material. When neither of the conveyed layer (28) of material and the top previously built layer (22) of material contains an unsupported portion, a second set of steps (304, 406, 504) are used to transfer the conveyed layer (28) of material to the top previously built layer (22) of material.
46.
METHOD OF THERMALLY TRANSFERRING IMAGES IN A SELECTIVE DEPOSITION BASED ADDITIVE MANUFACTURING SYSTEM
Disclosed are selective deposition based additive manufacturing systems (10) and methods for printing a 3D part. Layers of a powder material (22) are developed using one or more electrostatography-based engines (12). The layers (22) are transferred for deposition on a part build surface. For each of the layers (22), the part build surface is heated to a temperature within a range between a flowable temperature and a thermal oxidation threshold to form a flowable part build surface, and the developed layer (22) is pressed into contact with the flowable build surface (88) to heat the developed layers (22) to a flowable state and form a new part build surface (88) which is fully consolidated. The new part build surface (88) is then cooled to remove the heat energy added during heating step before repeating the steps for the next developed layer.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
47.
Height control in selective deposition based additive manufacturing of parts
A method of operating a selective deposition based additive manufacturing system capable of producing a three-dimensional (3D) part includes developing a first layer using at least one electrostatography engine, transfusing the first layer on a part build surface using a transfusion assembly to build the 3D part in a layer-by-layer manner on a part build platform such that a portion of the first layer further builds a fiducial structure in a layer-by-layer manner on the part build platform, measuring a height of the fiducial structure, computing an error between the measured height of the fiducial structure and a target height, adjusting a parameter of the at least one electrostatography engine as a function of the error, developing a second layer using the at least one electrostatography engine in accordance with the adjusted parameter, and transfusing the second layer using the transfusion assembly to further build the 3D part.
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
G03G 15/00 - Apparatus for electrographic processes using a charge pattern
A method of producing a 3D part using a selective deposition based additive manufacturing system can include developing a first layer using at least one electrostatography engine, determining a first cross-track offset distance between an average cross-track symmetry line of the first layer and a centerline of a transfer medium, transferring the first layer to the transfer medium such that the average cross-track symmetry line of the first layer is aligned with the centerline of the transfer medium, moving a build platform relative to the transfer medium in the cross-track direction to align the first layer on a part build surface, and transfusing the first layer on the build platform using a transfusion assembly to build the part in a layer-by-layer manner. The first layer comprises at least one of a part material and a support material. The first cross-track offset distance is measured in a cross-track direction perpendicular to an in-track direction of movement of the transfer medium.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
A selective-deposition-based additive manufacturing system (10) includes a transfer medium (24) configured to receive the layers (22) from an imaging engine (12), a heater (72) configured to heat the layers (22) on the transfer medium (24), and a layer transfusion assembly (20) that includes a build platform (28), and is configured to transfuse the heated layers (22) onto the build platform (28) in a layer-by-layer manner to print a three- dimensional part (22). The transfusion assembly (20) includes a nip roller (320) configured to deform when transfusing the heated imaged layers (22) to reduce deformation of the layers (22).
A part material for printing three-dimensional parts with a selective deposition-based additive manufacturing system has a composition having a thennoplastic polyuiethane polymer and a charge control agent. The part material is provided in a powder form having a D90/D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 1.40, wherein the part material is configured for use in the selective deposition-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/223 - Foils or films, e.g. for transferring layers of building material from one working station to another
An electrophotography-based additive manufacturing system (e.g., 10; 100; 200; 300; 350; 500; 700) having at least one electrophotography (EP) or electrostatographic engine (e.g., 12; 12p; 12s; 612p; 612p; 712-1; 712-2) and being configured such that a plurality of independently movable parts is built in parallel at a plurality of decoupled processing stations.
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
52.
SYSTEMS AND METHODS FOR ELECTROPHOTOGRAPHY-BASED ADDITIVE MANUFACTURING OF PARTS UTILIZING VARIABLE PRINTING PATHS
An electrostatic -based layer-wise manufacturing system (e.g., 200; 200-1; 250; 282; 300) decouples a layer imaging process from a layer transfusion process. The layer imaging process is performed in a first batch process that is independent from the layer transfusion process that is performed in a second batch process
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
53.
Layer transfusion for heat capacitor belt for additive manufacturing
An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/20 - Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
G03G 15/24 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups whereby at least two steps are performed simultaneously
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
54.
Electrophotography-based additive manufacturing with support structure and support structure removal
A method of printing a part using an additive manufacturing system includes identifying a part or parts to print and orienting a digital representation of the part(s) in a build volume. A digital representation of porous support structures for the part(s) is generated to form a digital representation of a part block of the part(s) to be printed. In the part block, a porosity of the support structure increases as a distance from an outer surface of the part increases within the print volume. The digital representation of the part block, including the part(s) and porous support structures, is sliced for printing.
B29C 33/44 - Moulds or coresDetails thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
B29C 33/52 - Moulds or coresDetails thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
B29C 67/00 - Shaping techniques not covered by groups , or
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
B29C 64/176 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects sequentially
B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/386 - Data acquisition or data processing for additive manufacturing
A method (200, 500) of printing a part (306) using an additive manufacturing system (10) includes identifying a part or parts (306) to print and orienting a digital representation of the part(s) (306)in a build volume. A digital representation of porous support structures (404) for the part(s) (306) is generated to form a digital representation of a part block (300) of the part(s) (306) to be printed. In the part block (300), a porosity of the support structure (404) increases as a distance from an outer surface of the part (306) increases within the print volume. The digital representation of the part block (300), including the part(s) (306)and porous support structures (404), is sliced for printing.
A method for printing a three-dimensional part with an electrophotography-based additive manufacturing system having an electrophotography engine, a transfer medium, and a layer transfusion assembly includes providing a part material to the electrophotography-based additive manufacturing system, the part material compositionally comprising a charge control agent, and a thermoplastic material having a heat deflection temperature greater than about 150° C., and has a powder form. The method includes triboelectrically charging the part material to a Q/M ratio having a negative charge or a positive charge, and a magnitude ranging from about 5 micro-Coulombs/gram to about 50 micro-Coulombs/gram and developing layers of the three-dimensional part from the charged part material with the electrophotography engine. The method includes electrostatically attracting the developed layers from the electrophotography engine to the transfer medium and moving the attracted layers to the layer transfusion assembly with the transfer medium, wherein the layer transfusion assembly comprises a nip roller. The method includes transfusing the moved layers to previously-printed layers of the three-dimensional part with by moving the attracted layers about a nip of a nip roller using heat and pressure over time.
G03G 13/22 - Processes involving the combination of more than one step according to groups
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 70/00 - Materials specially adapted for additive manufacturing
G03G 13/08 - Developing using a solid developer, e.g. powder developer
G03G 15/24 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups whereby at least two steps are performed simultaneously
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
B29K 71/00 - Use of polyethers as moulding material
B29K 105/00 - Condition, form or state of moulded material
B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
B29K 77/00 - Use of polyamides, e.g. polyesteramides, as moulding material
58.
Additive manufacturing using density feedback control
A method for printing a three-dimensional part with an additive manufacturing system includes providing a bitslice stack having a plurality of bitslices and printing a plurality of successive layers of the three-dimensional part with the additive manufacturing system based on the bitslices in the bitslice stack. The method includes measuring density of the three-dimensional part under construction near an intermediate build surface after one or more of the successive layers are printed. The method includes determining differences across the intermediate build surface of the measured density to a targeted density to identify one or more density error regions across the intermediate build surface, wherein the density error regions comprise low density regions, and modifying the bitslice stack to compensate for the one or more density error regions.
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
An additive manufacturing method produces a 3D part utilizes electrophotography-based additive manufacturing and molding processes. A layered structure having a cavity is printed on a build platform using at least one electrophotographic (EP) engine to develop imaged layers of powder material, and a transfusion assembly to stack and fuse the imaged layers on the build platform. Molding material is deposited into the cavity as the layered structure is printed, using a deposition unit. The molding material solidifies to form at least a portion of the 3D part, which may also include portions formed from imaged powder material.
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
G03G 15/00 - Apparatus for electrographic processes using a charge pattern
B29C 64/141 - Processes of additive manufacturing using only solid materials
B29C 70/74 - Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/20 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
A laser assembly for use with an additive manufacturing system, which includes a base block configured to be moved along a scan direction axis in the additive manufacturing system, a plurality of laser emitters preferably arranged in an array of at least two rows of two or more laser emitters. At least a portion of a heat sink assembly is configured to draw heat away from the base block and/or the laser emitters. The assembly includes a controller assembly a controller assembly configured to control a movement of the base block along the first axis and to independently control at least timing and duration of energy emitted from each laser emitter of the plurality of laser emitters as the base block moves along the first axis.
H01S 5/40 - Arrangement of two or more semiconductor lasers, not provided for in groups
H01S 5/02 - Structural details or components not essential to laser action
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
H01S 5/02325 - Mechanically integrated components on mount members or optical micro-benches
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having a grafted copolymer (including acrylonitrile units, butadiene units, aromatic units modified with polycarbonate and poly(styrene-co-maleimide)), a charge control agent, and a heat absorber. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
C09D 135/06 - Copolymers with vinyl aromatic monomers
C09D 151/00 - Coating compositions based on graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bondsCoating compositions based on derivatives of such polymers
C09D 169/00 - Coating compositions based on polycarbonatesCoating compositions based on derivatives of polycarbonates
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/24 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups whereby at least two steps are performed simultaneously
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/141 - Processes of additive manufacturing using only solid materials
B29K 55/02 - ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
B29K 69/00 - Use of polycarbonates as moulding material
B29K 25/00 - Use of polymers of vinyl-aromatic compounds as moulding material
63.
Systems and methods for electrophotography-based additive manufacturing of parts
In a method of producing a 3D part using an electrophotography-based additive manufacturing system, a plurality of layers of a powder-based material are developed using at least one electrophotography (EP) engine. The developed layers are transferred to a transfer medium. The layers on the transfer medium are dried by heating the layers without fully fusing the powder-based material to itself using a dryer. This reduces a water content of the layers. The dried layers are heated on the transfer medium to at least a fusion temperature, at which the power-based material fuses together, using a pre-transfusion heater. The dried layers are then transfused together on a build platform using a transfusion assembly to build the part in a layer-by-layer manner.
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/24 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups whereby at least two steps are performed simultaneously
64.
BUILDING WITH CYLINDRICAL LAYERS IN ADDITIVE MANUFACTURING
An additive manufacturing system (100) for printing a three-dimensional part includes a build roller (116) that rotates while receiving part material (254, 368) such that layers of part material (254, 368) are formed on a cylindrical base (349) of the build roller (116) in a cylindrical scroll to form the three-dimensional part, wherein the part material (254, 368) of adjacent layers of part material (254, 368) are bonded together on the build roller (116), and wherein the three-dimensional part can be non-cylindrical.
A method of printing a part in an electrophotographic additive manufacturing system includes printing a part and associated support structure in a layer by layer manner, and providing a chamber in which printing is performed. The chamber is supported by a movable platform and the chamber is positioned about a movable platen. The movable platen is supported by the movable build platform. The movable platen is movable within the chamber on the movable build platform. An electrophotography-based additive manufacturing system for printing a three-dimensional part includes a transfer medium configured to receive and transfer imaged layers of a three-dimensional part, and a support from one or more imaging engines. The system includes a heater configured to heat the imaged layers on the transfer medium to at least a fusion temperature, and a layer transfusion assembly configured to transfuse the imaged layers to the build platen or a previously printed layer.
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
G03G 15/24 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups whereby at least two steps are performed simultaneously
G03G 15/00 - Apparatus for electrographic processes using a charge pattern
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
66.
Electrophotography-based additive manufacturing with support structure and boundary
A method of printing a part in an additive manufacturing system includes printing a support structure for the part, printing a boundary surrounding the support structure, and printing the part on the support structure. An additive manufacturing system for printing a three-dimensional part includes a transfer medium configured to receive and transfer imaged layers of a thermoplastic-based powder for a boundary, a thermoplastic-based powder for a support, and a thermoplastic-based powder for the part from at least two imaging engines, a heater configured to heat the imaged layers on the transfer medium to at least a fusion temperature of the thermoplastic-based powder, and a layer transfusion assembly including a build platform, the layer transfusion assembly being configured to transfuse the heated layers in a layer-by-layer manner onto the build platform to print the three-dimensional part.
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
G03G 15/24 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups whereby at least two steps are performed simultaneously
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/141 - Processes of additive manufacturing using only solid materials
67.
Soluble support material for electrophotography-based additive manufacturing
A support material for printing a support structure with an electrophotography-based additive manufacturing system, the support material including a composition having a charge control agent and a thermoplastic copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups, and anhydride groups, with a high anhydride conversion. The composition is provided in a powder form having a controlled particle size, and the support material is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the support structure in a layer-by-layer manner, and is at least partially soluble in an aqueous solution.
G03G 5/00 - Recording-members for original recording by exposure e.g. to light, to heat, to electronsManufacture thereofSelection of materials therefor
G03G 15/08 - Apparatus for electrographic processes using a charge pattern for developing using a solid developer, e.g. powder developer
G03G 5/06 - Photoconductive layersCharge-generation layers or charge-transporting layersAdditives thereforBinders therefor characterised by the photoconductive material being organic
A method of printing three-dimensional parts with an electrophotography-based additive manufacturing system, with a part material including a composition having an engineering-grade thermoplastic material and a charge control agent. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
B29C 67/24 - Shaping techniques not covered by groups , or characterised by the choice of material
B29C 43/00 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
G03G 15/08 - Apparatus for electrographic processes using a charge pattern for developing using a solid developer, e.g. powder developer
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29K 77/00 - Use of polyamides, e.g. polyesteramides, as moulding material
B29K 105/00 - Condition, form or state of moulded material
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
69.
Part material for electrophotography-based additive manufacturing
A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having a copolymer (including acrylonitrile units, butadiene units, and aromatic units), a charge control agent, and a heat absorber. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
In a method for printing a three-dimensional (3D) parts with an additive manufacturing system, a developed layer of an electrically charged powder material is produced on a transfer medium using an electrophotographic (EP) engine. The transfer medium and the developed layer are fed in a feed direction. A position of the developed layer on the transfer medium is detected using a first sensor having a first output that indicates the position. A position of a moveable build platform is adjusted relative to the transfer medium to reduce one or more overlay errors between the developed layer and an intermediate build surface of a three-dimensional structure retained on the moveable build platform based on the first output. The developed layer is transferred to the intermediate build surface using a pressing element.
A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having a semi-crystalline thermoplastic material and a charge control agent. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system. The method includes developing a support layer of the support structure from a soluble support material with a first electrophotography engine, and transferring the developed support layer from the first electrophotography engine to a transfer medium. The method also includes developing a part layer of the three-dimensional part from an ABS part material with a second electrophotography engine, and transferring the developed part layer from the second electrophotography engine to the transfer medium. The method further includes moving the attracted part and support layers to a layer transfusion assembly with the transfer medium, and transfusing the moved part and support layers together to previously-printed layers with the layer transfusion assembly.
B29C 41/02 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped articleApparatus therefor for making articles of definite length, i.e. discrete articles
B29C 67/00 - Shaping techniques not covered by groups , or
G03G 13/22 - Processes involving the combination of more than one step according to groups
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
B29C 64/141 - Processes of additive manufacturing using only solid materials
B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B33Y 70/00 - Materials specially adapted for additive manufacturing
B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
B29C 47/08 - Component parts, details or accessories; Auxiliary operations
B29K 33/00 - Use of polymers of unsaturated acids or derivatives thereof, as moulding material
B29K 25/00 - Use of polymers of vinyl-aromatic compounds as moulding material
B29K 105/00 - Condition, form or state of moulded material
B29K 9/06 - SB polymers, i.e. butadiene-styrene polymers
A method and system for printing a three-dimensional part, which includes rotating a transfer belt with a developed layer, scanning the developed layer on the rotating transfer belt, pressing the developed layer into contact with an intermediate build surface of the three-dimensional part retained on a moveable build platform, scanning the pressed layer on the three-dimensional part, comparing the scanned layers to detect an overlay error, and adjusting a position of the moveable build platform relative to the transfer belt to reduce the overlay error for a subsequent developed layer.
A method and system for printing a three-dimensional part, which includes printing a plurality of successive layers of the three-dimensional part with the additive manufacturing system based on bitslices in a bitslice stack, measuring surface heights of the successive layers after each of the successive layers are printed, determining differences between the measured surface heights and predicted stack heights of the bitslices, identifying one or more topographical error regions based on the determined differences, and modifying the bitslice stack to compensate for the one or more topographical error regions.
A method and system for printing a three-dimensional part, which includes producing a developed layer of a part material with one or more electrophotography engines of an additive manufacturing system, transferring the developed layer from the one or more electrophotography engines to a transfer assembly of the additive manufacturing system sintering the developed layer at the transfer assembly to produce a sintered contiguous film, cooling the sintered contiguous film down to a transfer temperature, and pressing the cooled sintered contiguous film into contact with an intermediate build surface of the three-dimensional part with a low applied pressure.
An additive manufacturing system for printing a three-dimensional part, which includes one or more electrophotography engines configured to develop layers of the three-dimensional part, a rotatable transfer belt configured to receive the developed layers from the electrophotography engine(s), a detector configured to measure powder densities of the developed layers on the rotatable transfer belt, and to transmit signals relating to the measured powder densities to a controller assembly, and a printing assembly configured to receive the developed layer from the rotatable transfer belt and to print the three-dimensional part from the developed layers.
B29C 65/00 - Joining of preformed partsApparatus therefor
B29C 67/00 - Shaping techniques not covered by groups , or
G01N 27/22 - Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating capacitance
G01R 1/18 - Screening arrangements against electric or magnetic fields, e.g. against earth's field
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
An additive manufacturing system and process for printing a three-dimensional part, which includes one or more electrophotography engines configured to develop layers of the three-dimensional part, a printing assembly configured to print the three-dimensional part from the developed layers, and a planarizer configured to conduct solvent-assisted planarizations on intermediate build surfaces of the three-dimensional part after one or more of the developed layers are printed.
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
A support material for printing a support structure with an electrophotography-based additive manufacturing system, the support material including a composition having a charge control agent and a thermoplastic copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups, and anhydride groups, with a high anhydride conversion. The composition is provided in a powder form having a controlled particle size, and the support material is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the support structure in a layer-by-layer manner, and is at least partially soluble in an aqueous solution.
G03G 5/06 - Photoconductive layersCharge-generation layers or charge-transporting layersAdditives thereforBinders therefor characterised by the photoconductive material being organic
G03G 15/02 - Apparatus for electrographic processes using a charge pattern for laying down a uniform charge, e.g. for sensitisingCorona discharge devices
A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having a copolymer (including acrylonitrile units, butadiene units, and aromatic units), a charge control agent, and a heat absorber. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
A platen assembly for use in an additive manufacturing system, which includes a platen plate that is preferably secured to a gantry mechanism of the additive manufacturing system, and having a top surface, and one or more magnets secured to the platen plate and configured to generate one or more magnetic fields at the top surface of the platen plate. The platen gantry is configured to magnetically couple interchangeable and replaceable build sheets to the top surface of the platen plate due to the one or more generated magnetic fields, and where the magnetically-coupled build sheets are configured to receive the printed layers from the printing mechanism.
A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having an engineering-grade thermoplastic material and a charge control agent. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
A support material for printing a support structure with an electrophotography-based additive manufacturing system, the support material including a composition having a charge control agent and a thermoplastic copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups, and anhydride groups, with a high anhydride conversion. The composition is provided in a powder form having a controlled particle size, and the support material is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the support structure in a layer-by-layer manner, and is at least partially soluble in an aqueous solution.
A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system. The method includes developing a support layer of the support structure from a soluble support material with a first electrophotography engine, and transferring the developed support layer from the first electrophotography engine to a transfer medium. The method also includes developing a part layer of the three-dimensional part from an ABS part material with a second electrophotography engine, and transferring the developed part layer from the second electrophotography engine to the transfer medium. The method further includes moving the attracted part and support layers to a layer transfusion assembly with the transfer medium, and transfusing the moved part and support layers together to previously-printed layers with the layer transfusion assembly.
B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
B29C 41/02 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped articleApparatus therefor for making articles of definite length, i.e. discrete articles
B29C 67/00 - Shaping techniques not covered by groups , or
G03G 13/22 - Processes involving the combination of more than one step according to groups
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B33Y 70/00 - Materials specially adapted for additive manufacturing
A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having a copolymer (including acrylonitrile units, butadiene units, and aromatic units), a charge control agent, and a heat absorber. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.
An additive manufacturing system for printing a three-dimensional part using electrophotography, the additive manufacturing system comprising a rotatable photoconductor component, first and second development stations configured to develop layers of materials on a surface of the rotatable photoconductor component while the rotatable photoconductor component rotates in opposing rotational directions, and a platen configured to operably receive the developed layers in a layer-by-layer manner to print the three-dimensional part from at least a portion of the received layers.
An additive manufacturing system for printing a three-dimensional part using electrophotography, the additive manufacturing system including a rotatable photoconductor component, a development station configured to develop layers of a material on a surface of the rotatable photoconductor component, a rotatable transfer medium configured to receive the developed layers from the surface of the rotatable photoconductor component, and a platen configured to receive the developed layers from the rotatable transfer medium in a layer-by-layer manner. The additive manufacturing system also includes a plurality of service loops configured to move portions of the rotatable transfer medium at different line speeds while maintaining a net rotational rate of full rotations of the rotatable transfer medium at a substantially steady state.
An additive manufacturing system for printing a three-dimensional part using electrophotography, the additive manufacturing system comprising a rotatable photoconductor component, first and second development stations configured to develop layers of materials on a surface of the rotatable photoconductor component while the rotatable photoconductor component rotates in opposing rotational directions, and a platen configured to operably receive the developed layers in a layer-by-layer manner to print the three-dimensional part from at least a portion of the received layers.
An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.
B29C 67/00 - Shaping techniques not covered by groups , or
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.
B29C 67/00 - Shaping techniques not covered by groups , or
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
91.
Layer transfusion with rotatable belt for additive manufacturing
An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.
G03G 15/16 - Apparatus for electrographic processes using a charge pattern for transferring a pattern to a second base of a toner pattern, e.g. a powder pattern
G03G 15/22 - Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups
B29C 67/00 - Shaping techniques not covered by groups , or
G03G 15/20 - Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat
An additive manufacturing system for printing a three-dimensional part using electrophotography, the additive manufacturing system including a rotatable photoconductor component, a development station configured to develop layers of a material on a surface of the rotatable photoconductor component, a rotatable transfer medium configured to receive the developed layers from the surface of the rotatable photoconductor component, and a platen configured to receive the developed layers from the rotatable transfer medium in a layer-by-layer manner. The additive manufacturing system also includes a plurality of service loops configured to move portions of the rotatable transfer medium at different line speeds while maintaining a net rotational rate of full rotations of the rotatable transfer medium at a substantially steady state.
