公开(公告)号：US20250162262A1

公开(公告)日：2025-05-22

申请号：US18725345

申请日：2022-12-29

Applicant: Evolve Additive Solutions, Inc.

Inventor： Jerry Pickering ,  Brian Mullen

IPC: B29C64/40 ,  B29C64/141 ,  B33Y10/00 ,  C08K3/36 ,  C09D7/40 ,  C09D7/61 ,  C09D133/02

Abstract: 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.

公开(公告)号：US20250065559A1

公开(公告)日：2025-02-27

申请号：US18728677

申请日：2023-01-13

Applicant: Evolve Additive Solutions, Inc.

Inventor： Brian Mullen

IPC: B29C64/141 ,  B29C64/188 ,  B29C64/40 ,  B33Y10/00 ,  B33Y40/20

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.

公开(公告)号：US12083747B2

公开(公告)日：2024-09-10

申请号：US17611751

申请日：2020-05-15

Applicant: Evolve Additive Solutions, Inc.

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

IPC: B29C64/141 ,  B29C64/176 ,  B29C64/194 ,  B29C64/245 ,  B29C64/295 ,  B29C64/364 ,  B29C64/393 ,  G03B13/16 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

CPC classification number: B29C64/393 ,  B29C64/176 ,  B29C64/194 ,  B29C64/245 ,  B29C64/295 ,  B29C64/364 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

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：US12036727B2

公开(公告)日：2024-07-16

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 ,  B29C64/393 ,  B33Y50/02 ,  G03G15/22 ,  B33Y30/00

CPC classification number: B29C64/147 ,  B29C64/393 ,  B33Y50/02 ,  G03G15/224 ,  B33Y30/00

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：US11934129B2

公开(公告)日：2024-03-19

申请号：US17765325

申请日：2020-09-30

Applicant: Evolve Additive Solutions, Inc.

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

IPC: G03G15/00 ,  B29C64/188 ,  G03G15/20 ,  G03G15/22 ,  B33Y10/00 ,  G03G15/16 ,  G03G15/34

CPC classification number: G03G15/224 ,  B29C64/188 ,  G03G15/2021 ,  G03G15/2064 ,  B33Y10/00 ,  G03G15/167 ,  G03G15/344

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.

公开(公告)号：US20230256669A1

公开(公告)日：2023-08-17

申请号：US18016224

申请日：2021-07-15

Applicant: Evolve Additive Solutions, Inc.

Inventor： Zeiter Farah ,  J. Samuel Batchelder ,  Manish Boorugu ,  Brian Mullen ,  Alex J. Kossett

IPC: B29C64/147 ,  B29C64/223 ,  B29C64/40

CPC classification number: B29C64/147 ,  B29C64/223 ,  B29C64/40 ,  B33Y10/00

Abstract: 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.

公开(公告)号：US10996602B2

公开(公告)日：2021-05-04

申请号：US16232585

申请日：2018-12-26

Applicant: Evolve Additive Solutions, Inc.

Inventor： Andrew Rice ,  Zeiter Farah

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

Abstract: 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.

公开(公告)号：US20200368964A1

公开(公告)日：2020-11-26

申请号：US16966317

申请日：2019-02-01

Applicant: Evolve Additive Solutions, Inc.

Inventor： J. Samuel Batchelder

IPC: B29C64/223 ,  B33Y10/00 ,  B29C64/153 ,  B29C64/295 ,  B33Y30/00 ,  B29C64/245 ,  B29C64/393 ,  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：US20200249591A1

公开(公告)日：2020-08-06

申请号：US16648996

申请日：2018-09-20

Applicant: Evolve Additive Solutions, Inc.

Inventor： Maura A. Sweeney ,  Trevor I. Martin ,  Mark E. Mang

IPC: G03G9/087 ,  B33Y10/00 ,  B33Y70/00 ,  B33Y40/10 ,  G03G15/22 ,  B29C64/147 ,  B29C64/314 ,  G03G9/097 ,  G03G9/08

Abstract: A part material for printing three-dimensional parts with a selective deposition-based additive manufacturing system has a composition having a thermoplastic 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.

公开(公告)号：US10557056B2

公开(公告)日：2020-02-11

申请号：US15392479

申请日：2016-12-28

Applicant: Evolve Additive Solutions, Inc.

Inventor： Maura A. Sweeney ,  Mark E. Mang ,  Susan LaFica

IPC: B29C67/00 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y70/00 ,  C09D125/08 ,  C09D135/06 ,  C09D151/00 ,  C09D169/00 ,  C08L55/02 ,  B29C64/40 ,  G03G15/16 ,  G03G15/24 ,  G03G15/22 ,  B29C64/141 ,  B29K55/02 ,  B29K69/00 ,  B29K25/00

Abstract: 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.