Xerox Corporation

Marc Dennis Daniels

Jeffrey William Drawe

Sudhendu Rai

James J Spence

Michael Robert Furst

Jack Gaynor Elliot

Wayne A Buchar

Naveen G Sharma

Tracy Eugene Thieret

Robert J St Jacques, Jr

Claude Fillion

Mary Catherine McCorkindale

Michael P Kehoe

Arturo M Lorenzo

John C Austin

Michael F Cavanaugh

Weixia Huang

Husein Naser Rashed

David Allen Mantell

Peter Johan Nystrom

Paul Michael Fromm

Roger Gaylord Leighton

Eric Michael Gross

Martin Sidney Maltz

Mark A Atwood

Roger Lee Triplett

Paul N Richards

Jonathan Ross Ireland

Sharath Srinivas

Kelly J Burton

Ranjit Kumar Ettam

Raja Muthukrishnan Kalpana Padma

An addition to additive manufacturing sews a number of printed substrate sheets together using industrial sewing machine technology. Portions of the final 3D object that will be solid are sewn together into bundles of the object with a needle protruding through the top of the bundle via a sewing machine with a looping mechanism connecting the thread loops under each bundle of printed substrate sheet layers. This will result in many well connected stack bundles that are then stacked in alignment to form the final stack. During heat and compression, the stitch thread may bunch together and become entangled with the cooled plastic of the final solid 3D object. Removal of the excess substrate may proceed as usual, since the sewing is applied only in the solid portions of the final object. The end result will be a part with much higher strength in the Z axis.

Sewing method and apparatus to increase 3D object strength

An additive manufacturing system and method for improving the certainty of removing or etching excess substrate from a stack of printed substrate slices to arrive at a 3D object. The approach includes printing a pseudo image as a shell layer around a desired object slice with less polymer (e.g., thermoplastic) material than the 3D object solid layer slice. This slows the etching process when this pseudo image is reached. The pseudo image may be printed to surround the object polymer image on a printed substrate sheet as a shell that provides notice during the excess substrate removal/cleaning process that the desired polymer image is nearby and extra care must be taken to avoid removal of the desired polymer image. The pseudo image may have a 3D patterned surface that can be recognized by a person doing the sandblasting or recognized automatically by an automated 3D object finisher.

Patterned pre-stop for finishing additive manufactured 3D objects

A method and structure for forming conductive structure such as an electric circuit, or a portion of an electric circuit, can include the use of a thermal print head and a ribbon including a carrier and a metal layer. The thermal print head is used to print a first portion of the metal layer onto a sacrificial print medium. The first portion printed has a first pattern, where a second portion having a second pattern remains on the carrier. The first pattern is a reverse image at least a portion of the electric circuit, while the second pattern includes at least a portion of the electric circuit. The second portion having the second pattern can be transferred to a circuit substrate, then used as an electric circuit.

Radio-frequency identification (RFID) label or conductive trace thermal transfer printing method

A 3D printing system applies colored powders (e.g., primary colors, white, black, cyan, magenta, yellow, fluorescent colors, metallic) in printed polymer layers for forming a colored 3D object. The system may stabilize a powder layer or color sub-layers thereof, for example with one or more of heat, pressure, and/or high-intensity light. On each layer, powders of various colors may be sequentially deposited in a halftone pattern and stabilized, so as to create a part with a specified arrangement of colors throughout its structure. Benefits include more stable color than strategies involving jetting colored fluids. The arrangement of color on the interior of the part could provide functional or traceability benefits for specific applications. The examples allow for depositing a greater quantity of powder on each fiber base or substrate, decreasing the ratio of fiber to powder and increasing production speed.

Additive manufacturing system for halftone colored 3D objects

An additive manufacturing system for fabricating multi-sided printed composite sheet structures includes a roll fed duplex architecture that prints polymer images on both sides of a substrate sheet to form two-sided 3D composite layers. A substrate web is fed into the machine, and a top side is printed with a wetting agent, powdered, and the excess powder is removed. The image may be pinned to the substrate in a fusing step so that the web can be inverted to print a second image on the other side. The inversion architecture could include inverting rollers, tubes or a Mobius strip that may flip the substrate for backside printing using a single imaging station. The resulting two-side powdered and pinned substrate would then be cut, stacked, heated and compressed to create a 3-D object with more polymer in the stack, resulting in better adhesive binding characteristics at a much higher production speed.

Apparatus and method for fabricating multi-sided printed composite sheet structures

Apparatus and methods are disclosed for reclaiming unused powder in a composite-based additive manufacturing process. According to aspects of the embodiments, there is provided process and apparatus that use a substrate layer frame inversion mechanism that can flip the substrate over 180 degrees. The excess powder will simply drop into a waste reclaim container for later reuse. An optional mechanical vibrator may be used to completely loosen any remaining powder.

Composite-based additive manufacturing (CBAM) use of gravity for excess polymer removal

Apparatus and methods are disclosed to provide a guide for sand blasting a fiber-reinforced object. The proposed guide consist of three-dimensional (3D) features that will result in reflective ray-like protrusions that can be detected and displayed by Augmented Reality (AR) hardware including a head mounted display. The AR hardware determines a virtual object to be presented in a field of view, a position in the field of view, and a perspective of the virtual object in the field of view based on position information from the reflective ray-like protrusions. At least a portion of the sand blasting area is observable through the display and lens when the display is presenting the rendered virtual object.

Composite-based additive manufacturing (CBAM) augmented reality assisted sand blasting

According to aspects of the embodiments, there is provided process and apparatus to analyze imaging problems including but not limited to detecting defects of an imaging substrate useful in a Composite-Based Additive Manufacturing (CBAM) process. Data from the at least one imaging sensor may be used to: compensate for irregularities in a substrate deposited layer; compensate for irregularities in the printed layer, such as missing jet correction; reject a layer, the layer being scrapped and re-printed; pause the print job so that maintenance or service may be performed; or provide traceability data for proof-of-work, forensic, diagnostic, or other purposes. Depending on system architecture and design goals, the imaging sensor may be employed prior to or subsequent to the deposition of a printed layer.

Composite-based additive manufacturing (CBAM) image quality (IQ) verification and rejection handling

An object printer is configured to generate a three-dimensional map of a surface of an object to be printed and determine which areas in the three-dimensional map can be printed by a printhead movable in three-dimensional space. Areas can be printed when the printhead is positioned opposite an area where no inkjet in the printhead is closer than a minimum distance for accurate ink drop placement and all of the features in the area are within a maximum distance for accurate ink drop placement from the printhead. The areas that cannot be printed are deleted from the map and the map is displayed so a user can select where an ink image is to be formed on the object. The printer then operates an articulated arm to move the printhead opposite the surface at positions corresponding the selected area and operates the printhead to form the ink image.

System and method for analyzing the surface of a three-dimensional object to be printed by a printhead mounted to an articulating arm

According to aspects of the embodiments, there is provided process and apparatus to use additives with the clear wetting agent to aid in detection of defective substrates or missing jets. For light colored substrates, dye can be used for darkening of the wetting agent to provide sufficient contrast for defect detection. For dark colored substrates, the dye could be a specific color that a sensor is tuned for. An additive that glows only in the presence of a specific wave length of light could be utilized for any color substrate. By comparing the detected pattern to the desired pattern, end product voids can be greatly reduced or eliminated.

Wetting agent additive for an in-line quality check of composite-based additive manufacturing (CBAM) substrates

An inkjet printer adjusts operation of a vacuum system coupled to a printhead to compensate for pressure changes in the manifold of the printhead caused by vertical displacement of the printhead within the printer. The inkjet printer includes a controller that determines either a difference between an optimal pressure in the manifold and a current pressure to operate a vacuum coupled to the manifold for pressure adjustment or it correlates a current printhead vertical position to a previously observed vertical position and uses a vacuum value associated with the previously observed vertical position to operate the vacuum.

System and method for attenuating ink weeping and air ingestion in a printhead moved by an articulating arm

A print head includes a backup plate and a nozzle plate. The backup plate has a non-planar lower surface. The nozzle plate also has a non-planar lower surface. The nozzle plate is coupled to the lower surface of the backup plate.

Print head with curved nozzle plate

A method of analyzing failures of a print device may include receiving failure information associated with a print device in a print shop. The failure information may pertain to a plurality of failures experienced by the print device over a period of time. The method may include generating, by a computing device, failure distribution information by, for each pair of consecutive failures in the failure information, determining a time to failure between the pair of consecutive failures, determining a repair time associated with each failure in the pair of consecutive failures, and setting the determined times to failure and the determined repair times as the failure distribution information. The method may include performing, by the computing device, a simulation of processing of one or more print jobs by the print device using the failure distribution information, and displaying one or more results of the simulation to a user.

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Webster, NY, United States of America

Marc Dennis Daniels