Stratasys, Inc.

Evolve Additive Solutions, Inc.

Steven A Chillscyzn

William J Hanson

J Randolph Sanders

Michael W Bacus

J Samuel Batchelder

James W Comb

Trevor I Martin

James E Orrock

David M Kozlak

Arun Chowdry

Paul E Hopkins

Blake Zachary Courter

Zeiter Farah

Jonathan Bennhard Hedlund

An electrostatic-based layer-wise manufacturing system (e.g.,-) decouples a layer imaging process from a layer transfusion process. The layer imaging process is performed in a first batch process that is independent from the layer transfusion process that is performed in a second batch process.

Systems and methods for electrophotography-based additive manufacturing of parts utilizing multiple printing paths

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.

Layer transfusion for heat capacitor belt for additive manufacturing

A method for printing a three-dimensional part with an electrophotography-based additive manufacturing system having an electrophotography engine, a transfer medium, and a layer transfusion assembly includes providing a part material to the electrophotography-based additive manufacturing system, the part material compositionally comprising a charge control agent, and a thermoplastic material having a heat deflection temperature greater than about 150&#xb0; C., and has a powder form. The method includes triboelectrically charging the part material to a Q/M ratio having a negative charge or a positive charge, and a magnitude ranging from about 5 micro-Coulombs/gram to about 50 micro-Coulombs/gram and developing layers of the three-dimensional part from the charged part material with the electrophotography engine. The method includes electrostatically attracting the developed layers from the electrophotography engine to the transfer medium and moving the attracted layers to the layer transfusion assembly with the transfer medium, wherein the layer transfusion assembly comprises a nip roller. The method includes transfusing the moved layers to previously-printed layers of the three-dimensional part with by moving the attracted layers about a nip of a nip roller using heat and pressure over time.

Method of printing parts with a high-performance consumable materials with electrophotography based additive manufacturing system

In a method of producing a 3D part using an electrophotography-based additive manufacturing system, a plurality of layers of a powder-based material are developed using at least one electrophotography (EP) engine. The developed layers are transferred to a transfer medium. The layers on the transfer medium are dried by heating the layers without fully fusing the powder-based material to itself using a dryer. This reduces a water content of the layers. The dried layers are heated on the transfer medium to at least a fusion temperature, at which the power-based material fuses together, using a pre-transfusion heater. The dried layers are then transfused together on a build platform using a transfusion assembly to build the part in a layer-by-layer manner.

Systems and methods for electrophotography-based additive manufacturing of parts

A method of printing a part using an additive manufacturing system includes identifying a part or parts to print and orienting a digital representation of the part(s) in a build volume. A digital representation of porous support structures for the part(s) is generated to form a digital representation of a part block of the part(s) to be printed. In the part block, a porosity of the support structure increases as a distance from an outer surface of the part increases within the print volume. The digital representation of the part block, including the part(s) and porous support structures, is sliced for printing.

Electrophotography-based additive manufacturing with support structure and support structure removal

A continuous liquid interface production system includes a source of optical stimulation. The system includes a vessel configured to retain a pool or film of optically sensitive monomer and a substantially optically transparent plate retained by the vessel. The optical stimulation is directed through the plate and into the pool or the film based upon a sliced 3D model of the part. The system includes source of reaction inhibitor wherein the substantially optically transparent plate allows the reaction inhibitor to permeate through the plate and into the pool or the film such that a sufficient amount of reaction inhibitor is within the pool or the film to create a zone proximate the plate that prevents polymerization therein. A build platen is configured to be at least partially immersed into the pool or the film and above the zone as a part is initially being built, wherein a build platen actuator moves the build platen away from the pool or the film in a direction substantially normal to a top surface of the plate. A relative movement actuator provides relative movement between the plate and the part in a direction substantially parallel to the top surface of the plate such that a viscosity pump effect is created that forces monomer between the part being built and the plate.

Continuous liquid interface production system with viscosity pump

A method for building a three-dimensional object containing an identification-tag insert, the method comprising performing a build operation to form layers of the three-dimensional object using a layer-based additive technique, placing the identification-tag insert on at least a portion of the layers during the build operation, and reading information from the identification-tag insert.

Method for building and using three-dimensional objects containing embedded identification-tag inserts

A method of printing three-dimensional parts with an electrophotography-based additive manufacturing system, with a part material including a composition having an engineering-grade thermoplastic material and a charge control agent. 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.

Engineering-grade consumable materials for electrophotography-based additive manufacturing system

Layer transfusion with transfixing for additive manufacturing

Layer transfusion for additive manufacturing

A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having a semi-crystalline thermoplastic material and a charge control agent. 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.

Semi-crystalline consumable materials for electrophotography-based additive manufacturing system

Layer transfusion with rotatable belt for additive manufacturing

A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having an engineering-grade thermoplastic material and a charge control agent. 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.

Engineering-grade consumable materials for electrophotography-based additive manufacturing

An additive manufacturing system for printing a three-dimensional part using electrophotography, the additive manufacturing system comprising a rotatable photoconductor component, first and second development stations configured to develop layers of materials on a surface of the rotatable photoconductor component while the rotatable photoconductor component rotates in opposing rotational directions, and a platen configured to operably receive the developed layers in a layer-by-layer manner to print the three-dimensional part from at least a portion of the received layers.

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Victoria, MN, United States of America

Steven A Chillscyzn