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    ADDITIVE MANUFACTURING SYSTEM AND METHOD WITH IMPROVED SURFACE FINISH
    32.
    发明申请
    ADDITIVE MANUFACTURING SYSTEM AND METHOD WITH IMPROVED SURFACE FINISH 有权

    公开(公告)号：US20220326645A1

    公开(公告)日：2022-10-13

    申请号：US17765325

    申请日：2020-09-30

    Applicant: Evolve Additive Solutions, Inc.

    Inventor： J. Samuel Batchelder ,  Manish Boorugu ,  Andrew Rice

    IPC: G03G15/22 ,  G03G15/20

    Abstract: 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.

    Sacrificial layers in selective deposition-based additive manufacturing of parts
    33.
    发明授权
    Sacrificial layers in selective deposition-based additive manufacturing of parts 有权

    公开(公告)号：US11446862B2

    公开(公告)日：2022-09-20

    申请号：US16958906

    申请日：2018-12-28

    Applicant: Evolve Additive Solutions, Inc.

    Inventor： Zeiter Farah ,  Andrew Rice

    IPC: B29C64/147 ,  B33Y10/00 ,  B33Y50/02 ,  B29C64/393 ,  G03G15/22 ,  G03G15/00 ,  B33Y30/00

    Abstract: 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.

    LAYER TRANSFUSION SEQUENCING FOR SELECTIVE DEPOSITION-BASED ADDITIVE MANUFACTURING
    34.
    发明申请
    LAYER TRANSFUSION SEQUENCING FOR SELECTIVE DEPOSITION-BASED ADDITIVE MANUFACTURING 有权

    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.

    SELECTIVE DEPOSITION-BASED ADDITIVE MANUFACTURING DEVICE AND METHOD OF PRINTING 3D PARTS WITH SEMI-CRYSTALLINE MATERIALS
    35.
    发明申请
    SELECTIVE DEPOSITION-BASED ADDITIVE MANUFACTURING DEVICE AND METHOD OF PRINTING 3D PARTS WITH SEMI-CRYSTALLINE MATERIALS 有权

    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.

    Layer orientation in selective deposition based additive manufacturing of parts
    37.
    发明授权
    Layer orientation in selective deposition based additive manufacturing of parts 有权

    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.

    Electrophotography-based additive manufacturing with support structure and boundary
    38.
    发明授权
    Electrophotography-based additive manufacturing with support structure and boundary 有权

    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.

    THERMAL PARTITIONING IN AN ELECTROSTATOGRAPHIC ADDITIVE MANUFACTURING SYSTEM
    40.
    发明申请
    THERMAL PARTITIONING IN AN ELECTROSTATOGRAPHIC ADDITIVE MANUFACTURING SYSTEM 审中-公开

    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.

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