公开(公告)号：US20220234299A1

公开(公告)日：2022-07-28

申请号：US17611751

申请日：2020-05-15

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder ,  Manish Boorugu ,  Zeiter Farah

IPC: B29C64/393 ,  B29C64/295 ,  B29C64/364 ,  B29C64/245 ,  B29C64/194 ,  B29C64/176

Abstract: 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.

公开(公告)号：US20220227040A1

公开(公告)日：2022-07-21

申请号：US17615366

申请日：2020-05-29

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder ,  Eric Carl Stelter

IPC: B29C64/147 ,  B29C64/295 ,  B29C64/218 ,  B29C64/321

Abstract: 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.

公开(公告)号：US11203150B2

公开(公告)日：2021-12-21

申请号：US16235587

申请日：2018-12-28

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder

IPC: B29C64/153 ,  B29C64/295 ,  B29C64/245 ,  B29C64/393 ,  B33Y50/02 ,  B29C64/223 ,  B29C64/176 ,  B33Y30/00 ,  B29C64/35 ,  B33Y10/00

Abstract: 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.

公开(公告)号：US10675858B2

公开(公告)日：2020-06-09

申请号：US15380668

申请日：2016-12-15

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder ,  S. Scott Crump

IPC: B33Y80/00 ,  B33Y10/00 ,  B29C64/40 ,  G03G15/24 ,  G03G15/16 ,  G03G15/22 ,  B29C64/141

Abstract: 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.

公开(公告)号：US20200079008A1

公开(公告)日：2020-03-12

申请号：US16562146

申请日：2019-09-05

Applicant: Evolve Additive Solutions, Inc.

Inventor： Arun Chowdry ,  James W. Comb ,  Chris Counts ,  J. Samuel Batchelder

IPC: B29C64/147 ,  G03G15/22 ,  B29C64/393 ,  B33Y50/02

Abstract: 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.

公开(公告)号：US11845221B2

公开(公告)日：2023-12-19

申请号：US16966317

申请日：2019-02-01

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder

IPC: B29C64/223 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B29C64/153 ,  B29C64/245 ,  B29C64/295 ,  B29C64/393

CPC classification number: B29C64/223 ,  B29C64/153 ,  B29C64/245 ,  B29C64/295 ,  B29C64/393 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: 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).

公开(公告)号：US20220362994A1

公开(公告)日：2022-11-17

申请号：US17771696

申请日：2020-10-23

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder

IPC: B29C64/20 ,  B33Y30/00 ,  G03G21/20

Abstract: 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.

公开(公告)号：US20220355542A1

公开(公告)日：2022-11-10

申请号：US17622554

申请日：2020-06-30

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder

IPC: B29C64/147 ,  B33Y10/00 ,  B33Y30/00 ,  G03G15/22

Abstract: 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.

公开(公告)号：US20200338815A1

公开(公告)日：2020-10-29

申请号：US16958909

申请日：2017-12-29

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder ,  Arun Chowdry ,  Chris Anton

IPC: B29C64/147 ,  B29C64/40 ,  B29C64/153 ,  B29C64/218 ,  B29C64/364

Abstract: 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.

公开(公告)号：US20190202113A1

公开(公告)日：2019-07-04

申请号：US16235587

申请日：2018-12-28

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder

IPC: B29C64/153 ,  B29C64/35 ,  B29C64/176 ,  B29C64/245 ,  B29C64/295

CPC classification number: B29C64/153 ,  B29C64/176 ,  B29C64/245 ,  B29C64/295 ,  B29C64/35 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

Abstract: 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.