公开(公告)号：US20230391976A1

公开(公告)日：2023-12-07

申请号：US18259911

申请日：2022-01-03

申请人： IMPOSSIBLE OBJECTS, LLC

发明人： Robert Swartz ,  Michael Vasquez ,  Buckley Crist ,  Eugene Gore

IPC分类号： C08J11/06 ,  B33Y70/00 ,  B33Y40/10 ,  B29B17/04 ,  B29C64/314

CPC分类号： C08J11/06 ,  B33Y70/00 ,  B33Y40/10 ,  B29B17/0404 ,  B29C64/314 ,  C08J2371/10 ,  B29B2017/042 ,  B29B2017/0224

摘要： Waste product from any of a variety of processes (injection molding, selective laser sintering) is processed to form powders that have particle size and distribution optimal for a 3D printing technology known as Composite Based Additive Manufacturing (CBAM). Alternative recycling processes include grinding and sieving, emulsion extruding, and liquid-liquid phase separation.

公开(公告)号：US11674207B2

公开(公告)日：2023-06-13

申请号：US17455118

申请日：2021-11-16

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  John Bayldon ,  Buckley Crist ,  Eugene Gore

IPC分类号： C22C47/02 ,  C22C47/06 ,  C22C47/20 ,  C22C49/14 ,  B33Y30/00 ,  B33Y40/00 ,  B29C64/194 ,  B29C64/205 ,  B29C64/165 ,  B22F10/10 ,  B22F12/00 ,  B22F10/66 ,  B22F7/04 ,  B29C67/00 ,  B33Y10/00 ,  B33Y80/00 ,  B29C64/112 ,  B22F10/73 ,  B22F12/53 ,  B22F10/62 ,  B22F3/02 ,  B22F3/10 ,  B22F7/06 ,  B22F7/08

CPC分类号： C22C47/025 ,  B22F7/04 ,  B22F10/10 ,  B22F10/66 ,  B22F12/00 ,  B29C64/165 ,  B29C64/194 ,  B29C64/205 ,  B29C67/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y80/00 ,  C22C47/062 ,  C22C47/20 ,  C22C49/14 ,  B22F3/02 ,  B22F3/1035 ,  B22F3/1039 ,  B22F7/062 ,  B22F7/08 ,  B22F10/62 ,  B22F10/73 ,  B22F12/53 ,  B22F2007/045 ,  B22F2201/01 ,  B22F2998/10 ,  B22F2999/00 ,  B29C64/112 ,  Y02P10/25 ,  B22F2998/10 ,  B22F10/10 ,  B22F3/02 ,  B22F3/1035 ,  C22C47/20 ,  B22F2998/10 ,  B22F10/10 ,  B22F3/02 ,  B22F3/1039 ,  C22C47/20 ,  B22F2999/00 ,  B22F10/10 ,  B22F7/08 ,  B22F2201/01 ,  B22F2999/00 ,  B22F10/10 ,  B22F7/062 ,  B22F2201/01

摘要： A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

公开(公告)号：US11667081B2

公开(公告)日：2023-06-06

申请号：US17211410

申请日：2021-03-24

申请人： Impossible Objects, Inc.

发明人： Eugene Gore

IPC分类号： B33Y40/00 ,  B29C64/329 ,  B29C64/357 ,  B29C64/141 ,  B33Y30/00 ,  B33Y10/00 ,  B29K101/12

CPC分类号： B29C64/357 ,  B29C64/141 ,  B29C64/329 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B29K2101/12

摘要： A double dump valve apparatus has the doors flap open in opposite horizontal orientations and directions.

公开(公告)号：US20210362421A1

公开(公告)日：2021-11-25

申请号：US17324554

申请日：2021-05-19

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Buckley Crist ,  Darren Fill ,  John Bayldon

IPC分类号： B29C64/35 ,  B33Y10/00 ,  B33Y40/20 ,  B29C64/165

摘要： A method of residual ink removal in an ink-dependent 3-D printing process includes pre-heating a build block to an evaporation temperature. This is preferably done after stacking and before compression. Later compression will then involve a higher temperature to allow fusing of thermoplastic material in the build block, but without residual ink.

公开(公告)号：US20210237359A1

公开(公告)日：2021-08-05

申请号：US17211410

申请日：2021-03-24

申请人： Impossible Objects, Inc.

发明人： Eugene Gore

IPC分类号： B29C64/357 ,  B29C64/141 ,  B29C64/329 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y10/00

摘要： A double dump valve apparatus possesses a space saving arrangement by having the doors flap open in opposite horizontal orientations and directions.

公开(公告)号：US20210229365A1

公开(公告)日：2021-07-29

申请号：US17156565

申请日：2021-01-23

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Leonard Wanger ,  John Bayldon ,  Jeff Saltzman ,  Charles Pint ,  Eugene Gore ,  Gintaras Vaisnys ,  Giovanni Meier ,  Alon Henson

IPC分类号： B29C64/393 ,  G06T7/00

摘要： A collection of camera-based monitoring sub-systems can be added to a composite-based additive manufacturing (CBAM) system to autonomously inspect the integrity of each layer and remediate issues in real time. Cameras are located at various stations throughout the process. Resulting images are analyzed to see if processed pages are within tolerance based on comparison with models. Cameras can be placed at the print platen, on a rear conveyor that conveys powdered pages to the stacker and in the stacker itself to make sure pages are stacked and aligned properly. The present invention provides quality assurance and quality control to validate the build process at the layer level. This reduces the amount of post-build labor to perform, and since it shows data internal to the part, it dramatically reduces the amount of destructive testing required.

公开(公告)号：US20200223131A1

公开(公告)日：2020-07-16

申请号：US16711313

申请日：2019-12-11

申请人： Impossible Objects Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Buckley Crist

IPC分类号： B29C64/141 ,  B29C65/48 ,  B32B5/02 ,  B32B9/04 ,  B32B5/16 ,  B32B5/30 ,  B32B29/04 ,  B32B29/02 ,  B32B27/06 ,  B32B18/00 ,  B32B5/22 ,  B32B27/08 ,  B32B27/10 ,  B32B27/12 ,  B32B5/12 ,  B32B29/00 ,  B32B5/26 ,  G03G15/22 ,  B29C64/153 ,  B32B9/00 ,  B29C64/20 ,  B32B9/06 ,  B32B27/36 ,  B32B27/14 ,  B32B7/14 ,  B29K105/00 ,  B33Y40/00 ,  B29K101/12 ,  B33Y10/00

摘要： A three-dimensional object comprises substantially planar or flat substrate layers that are folded and stacked in a predetermined order and infiltrated by a hardened material. The object is fabricated by positioning powder on all or part of multiple substrate layers. On each layer, the powder is selectively deposited in a pattern that corresponds to tiles that each have a slice of the object. For each slice, powder is deposited in positions that correspond to positions in the slice where the object exists, and not deposited where the object does not exist. The tiles of each substrate layer are folded and aligned in a predetermined order. Multiple folded substrate layers mat be combined into a single stack. The powder is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers.

公开(公告)号：US20240254344A1

公开(公告)日：2024-08-01

申请号：US18423920

申请日：2024-01-26

申请人： IMPOSSIBLE OBJECTS, INC.

发明人： Robert Swartz ,  Michael Vasquez ,  Buckley Crist ,  John Bayldon ,  Eugene Gore

IPC分类号： C09D7/40 ,  B33Y70/10 ,  C09D1/02 ,  C09D7/61 ,  C09D179/08 ,  C08K7/06 ,  C08K7/14

CPC分类号： C09D7/70 ,  B33Y70/10 ,  C09D1/02 ,  C09D7/61 ,  C09D179/08 ,  C08K7/06 ,  C08K7/14

摘要： Processes for producing CBAM parts and/or components, including resulting articles, are disclosed. In one process, a fiber substrate binder possessing a flash point temperature greater than a predetermined processing temperature is used.

公开(公告)号：US11969938B2

公开(公告)日：2024-04-30

申请号：US16775267

申请日：2020-01-28

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Buckley Crist ,  Michael Vasquez ,  John Bayldon

IPC分类号： B29C64/147 ,  B29C64/153 ,  B29C64/165 ,  B29C64/245 ,  B29C64/295 ,  B29K23/00 ,  B29K25/00 ,  B29K33/00 ,  B29K71/00 ,  B29K79/00 ,  B29K81/00 ,  B29K101/10 ,  B29K105/00 ,  B29K707/04 ,  B32B5/02 ,  B32B5/26 ,  B33Y10/00 ,  B33Y70/00 ,  B33Y70/10 ,  B33Y80/00

CPC分类号： B29C64/147 ,  B29C64/153 ,  B29C64/165 ,  B29C64/245 ,  B29C64/295 ,  B32B5/022 ,  B32B5/024 ,  B32B5/26 ,  B33Y10/00 ,  B33Y70/10 ,  B33Y80/00 ,  B29K2023/06 ,  B29K2023/12 ,  B29K2025/06 ,  B29K2033/12 ,  B29K2071/00 ,  B29K2079/085 ,  B29K2081/04 ,  B29K2101/10 ,  B29K2105/0097 ,  B29K2707/04 ,  B29K2713/00 ,  B29K2995/0094 ,  B32B2260/023 ,  B32B2260/046 ,  B32B2264/10 ,  B33Y70/00

摘要： A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material comprising engineered powder that is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers. The powder may be emulsion aggregation powder, chemically-produced toner powder, or a combination. It may be a thermoplastic or thermosettable polymer and may include nylon, elastomers, polyolefins, polyethylene, polyether ether ketone, polyimide, polyetherimide, polyphenylene sulfide, polystyrene, polypropylene, polymethyl methacrylate, and polyaryletherketone, or a combination. The powder particles may have a pre-specified controlled shape and/or a non-homogenous composition. Surface treatments and/or additives may be used to control powder flow and charge distribution. Each substrate layer may be a sheet-like structure comprising fibers held together by binder. The binder may include sodium silicate.

公开(公告)号：US11806935B2

公开(公告)日：2023-11-07

申请号：US17324554

申请日：2021-05-19

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Buckley Crist ,  Darren Fill ,  John Bayldon

IPC分类号： B29C64/35 ,  B29C64/165 ,  B33Y40/20 ,  B33Y10/00

CPC分类号： B29C64/35 ,  B29C64/165 ,  B33Y10/00 ,  B33Y40/20

摘要： A method of residual ink removal in an ink-dependent 3-D printing process includes pre-heating a build block to an evaporation temperature. This is preferably done after stacking and before compression. Later compression will then involve a higher temperature to allow fusing of thermoplastic material in the build block, but without residual ink.