公开(公告)号：US11993006B2

公开(公告)日：2024-05-28

申请号：US17615366

申请日：2020-05-29

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder ,  Eric Carl Stelter

IPC: B33Y10/00 ,  B29C64/147 ,  B29C64/218 ,  B29C64/295 ,  B29C64/321 ,  B33Y30/00 ,  B33Y40/20 ,  B33Y70/00

CPC classification number: B29C64/147 ,  B29C64/218 ,  B29C64/295 ,  B29C64/321 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/20 ,  B33Y70/00

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：US11904531B2

公开(公告)日：2024-02-20

申请号：US16958904

申请日：2018-12-28

Applicant: Evolve Additive Solutions, Inc.

Inventor： Chris Counts ,  J. Samuel Batchelder

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

CPC classification number: B29C64/147 ,  B33Y10/00 ,  G03G15/224 ,  B33Y30/00

Abstract: 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.

公开(公告)号：US11654624B2

公开(公告)日：2023-05-23

申请号：US16958909

申请日：2018-12-28

Applicant: Evolve Additive Solutions, Inc.

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

IPC: B29C64/218 ,  B29C64/147 ,  B29C64/364 ,  B29C64/153 ,  B29C64/40 ,  B33Y10/00 ,  B33Y30/00 ,  B22F12/63 ,  B22F10/40

CPC classification number: B29C64/218 ,  B29C64/147 ,  B29C64/153 ,  B29C64/364 ,  B29C64/40 ,  B22F10/40 ,  B22F12/63 ,  B33Y10/00 ,  B33Y30/00

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：US10792908B2

公开(公告)日：2020-10-06

申请号：US15386904

申请日：2016-12-21

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder ,  Arun Chowdry ,  Steven A. Chillscyzn

IPC: B29C64/40 ,  B33Y30/00 ,  G03G15/22 ,  B29C64/141 ,  G03G15/20 ,  B33Y10/00 ,  G03G15/16 ,  G03G15/24

Abstract: 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.

公开(公告)号：US20200307087A1

公开(公告)日：2020-10-01

申请号：US16796518

申请日：2020-02-20

Applicant: Evolve Additive Solutions, Inc.

Inventor： Chris Counts ,  J. Samuel Batchelder

IPC: B29C64/245 ,  B33Y10/00 ,  B33Y30/00

Abstract: Embodiments herein relate to substrates for use in a selective toner electrophotographic process (STEP) additive manufacturing system. The substrates include a build platform for use in STEP additive manufacturing system, the build platform comprising a build substrate for receiving a build material deposited by a STEP process; wherein the platform has selected thermal properties, such as within 30 percent of the build material to be deposited onto the substrate.

公开(公告)号：US10518486B2

公开(公告)日：2019-12-31

申请号：US15630781

申请日：2017-06-22

Applicant: Evolve Additive Solutions, Inc.

Inventor： Blake Zachary Courter ,  Zeiter Farah ,  Steven A. Chillscyzn ,  J. Samuel Batchelder

IPC: B29C33/44 ,  B29C33/52 ,  B29C67/00 ,  B33Y50/02 ,  B29C64/106 ,  B29C64/112 ,  B29C64/176 ,  B29C64/171 ,  G03G15/22 ,  B29C64/40 ,  B29C64/393 ,  B29C64/153 ,  B29C64/386 ,  B29K101/12 ,  B33Y80/00 ,  B33Y10/00 ,  B29K105/00

Abstract: 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.

公开(公告)号：US10144175B2

公开(公告)日：2018-12-04

申请号：US14218121

申请日：2014-03-18

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder

IPC: G03G15/22 ,  B29C64/188 ,  G03G15/16 ,  B33Y10/00 ,  B33Y30/00

Abstract: 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.