Xerox Corporation

Additive Technologies LLC

Dinesh Krishna Kumar Jayabal

David Allen Mantell

Christopher T Chungbin

Daniel R Cormier

Stuart Alan Schweid

Walter Hsiao

David G Tilley

PriyaankaDevi Guggilapu

Viktor Sukhotskiy

Palghat Srinivas Ramesh

Alexander J Fioravanti

Denis Cormier

David A Mantell

Manoj Meda

Paul J McConville

Steven Robert Moore

Kareem N Tawil

Collin A Ladd

Michael F Dapiran

Kareem Tawil

Benjamin Paulson

A method of operating a three-dimensional (3D) metal object manufacturing apparatus selects operational parameters for operation of the printer to form conductive metal traces on substrates with dimensions within appropriate tolerances and with sufficient conductive material to carry electrical currents without burning up or becoming too hot. The method identifies the material of the substrate and the bulk metal being melted for ejection and uses this identification data to select the operational parameters. Thus, the method can form conductive traces and circuits on a wide range of substrate materials including polymeric substrates, semiconductor materials, oxide layers on semiconductor materials, glass, and other crystalline materials.

Method for operating a metal drop ejecting three-dimensional (3D) object printer to form electrical circuits on substrates

A three-dimensional (3D) metal object manufacturing apparatus is operated to compensate for surface deviations of overhanging features differently than for non-overhanging features. The compensation technique used for the overhanging features depends on whether an edge of the overhanging feature being formed in a next layer has curved or sharp corners.

Method and apparatus for forming overhanging structures in additive manufactured parts that have an improved surface roughness

A method includes ejecting a plurality of drops of a build material from a nozzle of a 3D printer. The build material cools and solidifies after being ejected to form a 3D object. The method also includes controlling an oxidation of the drops, the 3D object or both to create different oxidation levels in first and second portions of the 3D object.

Atmosphere and part formation in a liquid metal drop-on-demand printer

A slicer in a material drop ejecting three-dimensional (3D) object printer identifies the positions and local densities for a plurality of infill lines within a perimeter to be formed within a layer of an object to be formed by the printer. The local density of each infill line is filtered and a control law is applied to the filtered local density to identify an error in the local density compared to a target density. This process is performed iteratively until the error is within a predetermined tolerance range about the target local density. The error is used to generate machine ready instructions to operate the 3D object printer to achieve the target density for the infill lines.

Method for improved infilling of part interiors in objects formed by additive manufacturing systems

A slicer in a material drop ejecting three-dimensional (3D) object printer determines the number of material drops to eject to form a perimeter in an object layer and distributes a quantization error over the layers forming the perimeter. The slicer also identifies the location for the first material drop ejected to form the perimeter using a blue noise generator.

System and method for operating a material drop ejecting three-dimensional (3D) object printer to prevent quantization error in perimeters of a three-dimensional printed object

A three-dimensional (3D) metal object manufacturing apparatus is operated to form sloping surfaces having a slope angle of more than 45&#xb0; from a line that is perpendicular to the structure on which the layer forming the slope surface is formed. The angle corresponds to a step-out distance from the perpendicular line and a maximum individual step-out distance determined from empirically derived data. Multiple passes of an ejection head of the apparatus can be performed within a layer to form a sloped edge and the mass of the sloped structure is distributed within the sloped edge so the edge is formed without defects.

Method and apparatus for forming overhang structures with a metal drop ejecting three-dimensional (3D) object printer

A three-dimensional (3D) object printer operates a radiation source to direct radiation emitted by the radiation source through a porous substrate at a first intensity insufficient to cure a material contained in the porous substrate and at a second intensity sufficient to cure the material after the emitted radiation has passed through the porous substrate. The material is applied to the porous substrate by one or more wipers.

System and method for additive manufacture of three-dimensional (3D) printed objects with UV-curable material using a porous substrate

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a wire detector to determine a position of a top surface of melted metal contained in a receptacle of a heated vessel in the apparatus from time to time. The solid metal wire being fed into the heated vessel is retracted and the length of the retracted wire is determined using a signal generated by the wire detector. The determined length of the wire is used to identify the position of the top level of the melted metal in the receptacle so the receptacle can be replenished if the level has fallen below a predetermined capacity for the receptacle.

Melted metal level sensor for a metal drop ejecting three-dimensional (3D) object printer

A three-dimensional (3D) metal object manufacturing apparatus selects operational parameters for operation of the printer to form conductive metal traces on substrates with dimensions within appropriate tolerances and with sufficient conductive material to carry electrical currents without burning up or becoming too hot. The apparatus identifies the material of the substrate and the bulk metal being melted for ejection and uses this identification data to select the operational parameters. Thus, the apparatus can form conductive traces and circuits on a wide range of substrate materials including polymeric substrates, semiconductor materials, oxide layers on semiconductor materials, glass, and other crystalline materials.

Method and system for operating a metal drop ejecting three-dimensional (3D) object printer to form electrical circuits on substrates

System and method for improved infilling of part interiors in objects formed by additive manufacturing systems

A three-dimensional (3D) printer includes an ejector and a heating element configured to heat a solid printing material in the ejector, thereby causing the solid printing material to change to a liquid printing material within the ejector. The 3D printer also includes a coil wrapped at least partially around the ejector. The 3D printer also includes a power source configured to supply one or more pulses of power to the coil, which cause one or more drops of the liquid printing material to flow out of the ejector through a nozzle of the ejector. The 3D printer also includes a gas-controlling device configured to control a gas in the 3D printer.

Growing community of inventors

Rochester, NY, United States of America

Dinesh Krishna Kumar Jayabal