Xerox Corporation

Jason O'Neil

Paul J McConville

David Allen Mantell

Peter Johan Nystrom

Christopher G Lynn

Anthony Salvatore Condello

Steven Robert Moore

Michael F Leo

Wayne A Buchar

Xin Yang

Vincent M Williams

David Peter Lomenzo

Reiner Eschbach

Barkev Keoshkerian

Jennifer Lynne Belelie

Mandakini Kanungo

Trevor James Snyder

Gerald A Domoto

Bryan James Roof

Nancy Y Jia

Jing Zhou

Kenneth Russell Ossman

Michelle N Chrétien

Alexander J Fioravanti

Lawrence Floyd, Jr

Wei Hong

Fusheng Xu

Jacques K Webster-Curley

Priyaanka D Guggilapu

Alexander J Fiorvanti

David P Lomenzo

A method of operating a multi-nozzle extruder in an additive manufacturing system enables support structure to be formed while an object is also being formed. The method includes opening more than one nozzle in the multi-nozzle extruder, and operating an actuator with a controller to move the multi-nozzle extruder along a path to form a first group of multiple parallel ribbons of support structure simultaneously with material extruded from the more than one open nozzle.

System and method for providing three-dimensional object structural support with a multi-nozzle extruder

An additive manufacturing system has a controller configured to modify numerical control programming instructions to form interlocking structures that improve object structural integrity in the Z-direction. The interlocking structures are produced by forming one layer with swaths that are separated by gaps and another layer that is formed over the gaps to fill the gaps and lay over the swaths forming the gaps.

System and method for operating a multi-nozzle extruder during additive manufacturing

A process including providing a substantially flat printed image on a substrate; disposing a curable gellant composition onto the printed image in registration with the printed image, successively depositing additional amounts of the gellant composition to create a raised image in registration with the printed image; and curing the deposited raised image. A process including providing a printed image on a substrate; disposing a curable non-gellant composition onto the printed image in registration with the printed image; and disposing a curable gellant composition onto the printed image in registration with the printed image; to create a raised image in registration with the printed image; and curing the deposited raised image. An ultraviolet curable phase change gellant composition including a radiation curable monomer or prepolymer, a photoinitiator, a silicone polymer or pre-polymer, and a gellant.

Method for applying curable gellant composition for digital embossing and other raised print applications

An additive manufacturing system opens the valves in an extruder needed to form a swath and operates an actuator to move the extruder through a transition region with those valves open to establish an amount of extrusion material between a faceplate of the extruder and a portion of an object being formed that is adequate for formation of a swath. The length of the transition region is determined with reference to a viscosity of the material being extruded and a speed at which the extruder is moved to form the swath. The transition region can be perpendicular to a path of the extruder to form the swath or aligned with the path of the extruder to form the swath.

Method for operating an extruder in a three-dimensional (3D) object printer to improve layer formation

A system for printing at least one stretchable ink on a thermoformable substrate including an unwinder arranged to feed the thermoformable substrate from a first roll into a web drive subsystem, a surface energy modification device arranged to alter a substrate surface energy to enhance wetting and adhesion of the at least one stretchable ink to the thermoformable substrate, at least one printhead array arranged to deposit the at least one stretchable ink on the thermoformable substrate, at least one radiation curing device arranged to cure the at least one stretchable ink on the thermoformable substrate, a sensor array arranged to monitor the at least one stretchable ink on the thermoformable substrate, and a rewinder arranged to receive the thermoformable substrate and to form the thermoformable substrate into a second roll.

Printing device and method of using the same

An additive manufacturing system operates an actuator to move an extruder with reference to a selected first zig-zag pattern to sparsely fill an interior region of an object by extruding a swath of thermoplastic material that has straight portions connected by angled portions. After a first pass using the first zig-zag pattern is completed, a second zig-zag pattern is used to form a complementary swath that forms rigid structure with the first swath. Use of the two patterns is alternated to sparsely fill the interior region in multiple layers of the object until a predetermined distance from a solid fill structure or surface is detected. Transition patterns are then used to increase the density of the swaths in the interior region in the next successive layers of the object until the layer is reached where a solid fill surface is formed over the swaths formed using the transition patterns.

Method for operating a multi-nozzle extruder using zig-zag patterns that provide improved structural integrity

A system for printing at least one stretchable ink on a thermoformable substrate including an unwinder arranged to feed the thermoformable substrate from a first roll into a web drive subsystem, a surface energy modification device arranged to alter a substrate surface energy to enhance wetting and adhesion of the at least one stretchable ink to the thermoformable substrate, at least one full width printhead array arranged to deposit the at least one stretchable ink on the thermoformable substrate, at least one radiation curing device arranged to cure the at least one stretchable ink on the thermoformable substrate, a full width array sensor arranged to monitor the at least one stretchable ink on the thermoformable substrate, and a rewinder arranged to receive the thermoformable substrate and to form the thermoformable substrate into a second roll.

An apparatus for distributing a hydrophobic material in a substrate includes a first roller, second roller that engages the first roller to form a nip, a heater operatively connected to the first roller and configured to heat the first roller to a first temperature that is greater than a second temperature of the second roller, and a substrate transport configured to move a substrate through the nip at a predetermined velocity. The first roller engages a first side of the substrate and the second roller engages a second side of the substrate to enable the hydrophobic material to penetrate into the substrate.

System and method for forming hydrophobic structures in a porous substrate

An approach is provided for controlling ultraviolet-curable gel ink spread of a printed image. The approach involves causing, at least in part, one or more inks to be applied to a first substrate image area by one or more inkjets in a printing zone of a printer, the one or more inkjets being configured to form one or more first ink spots on the first substrate image area. The approach also involves determining a temperature of at least the first substrate image area in the printing zone. The approach further involves determining a first spot size of at least one of the one or more first ink spots. The approach additionally involves causing, at least in part, a temperature of at least a second substrate image area in the printing zone to be based, at least in part, on the determined first spot size.

Method and apparatus for controlling ultraviolet-curable gel ink spread of a printed image

A scratch-off document may include a substrate bearing a toner image and a scratch-off layer covering the printed content. The scratch-off layer may include a mass of a first solid ink and a mass of a second solid ink printed over the first solid ink in a distraction pattern. The toner image is formed of a toner that adheres to the substrate, while the scratch-off layer is made of a wax-based or other solid ink that may be removed from the substrate by scratching without removing the toner image. The distraction pattern includes varying pile heights that distract a viewer from any pile height variations that may exist in the toner image.

Method and system of printing a scratch-off document

A method and apparatus for metering release agent on an imaging member includes applying a release agent to a rotating imaging member at an application location and then controlling a thickness of the release agent on the imaging member with a rotating metering roll. In at least one embodiment, the method for metering a release agent includes rotating the metering roll as a counter-roll to an imaging drum such that the metering roll moves in an opposite direction from the imaging drum at a nip between the metering roll and the imaging drum. The metering roll may include an elastomer provided over the substantial portion of its outer surface which contacts the imaging drum. The metering roll may also be forcibly biased against the imaging drum. At least one wiper blade may be provided in contact with the metering roll to wipe excess release agent from the metering roll.

Printer with release agent metering on drum

A method for detecting a defect in an inkjet print head for printing a substantially clear ink includes including an ultraviolet or infrared sensitive material in the substantially clear ink, marking a test image on a substrate by jetting the substantially clear ink through one or more jets of the inkjet print head to be evaluated, exposing the test image to activating radiation having a wavelength to which the included ultraviolet or infrared sensitive material responds. During or following the exposing, the test image is evaluated with an image sensor, and whether the inkjet print head or any one of the one or more jets thereof being evaluated is defective is then determined based on the evaluation. A system for the method is also set forth.

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Rochester, NY, United States of America

Jason O'Neil