Evolve Additive Solutions, Inc.

Stratasys, Inc.

Andrew Rice

Zeiter Farah

J Samuel Batchelder

Paul J Leavitt

Timothy A Hjelsand

Manish Boorugu

A method of additive manufacturing utilizing selective layer deposition includes measuring a transfuse force between a transfuse roller and a part build surface. An angular position of the transfuse roller is measured over time. A component of a transfuse force variation that is periodic in a rotational period of the transfuse roller is estimated, and a vertical position between the transfuse roller and the part build surface is adjusted to reduce pressure variations in transfuse roller force on the build part surface.

Transfuse roller tracking in selective layer deposition based additive manufacturing

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.

Additive manufacturing system and method with improved surface finish

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.

Sacrificial layers in selective deposition-based additive manufacturing of parts

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.

Height control in selective deposition based additive manufacturing of parts

An assembly for use in an additive manufacturing system to print a three-dimensional part that includes an extruder comprising a gear and a motor that turns the gear, wherein rotation of the gear regulates a flow of material out of the extruder. A controller, provides a control signal to the motor to control the rate at which the motor turns the at least one gear and incorporates a time-varying signal into the control signal to reduce ripples in the material output by the extruder.

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Chaska, MN, United States of America

Andrew Rice