Abstract: A method of manufacturing a three-dimensional object operates components in an additive manufacturing system with reference to quantifications identified for properties of different materials in a same layer. The method enables the layer to be formed with compensation for the differences in the quantifications of the properties of the two materials.

Abstract: A method of manufacturing a three-dimensional object operates components in an additive manufacturing system with reference to a difference between quantifications identified for different properties of at least two materials in a same layer. The method enables the layer to be formed with compensation for the differences in the quantifications of the properties of the two materials.

Abstract: A method of calibrating ejectors in an ejector head in a three-dimensional object printer normalizes the masses of the drops ejected by the ejectors. The method operates the plurality of ejectors to eject drops of material to form a plurality of pixels corresponding to a test pattern on the surface. Each ejector in the plurality of ejectors is operated to form a group of adjacent pixels in the test pattern. Each group of adjacent pixels is at least n pixels wide in a cross-process direction for the printer. The method operates a sensor to measure heights of pixels for each group of adjacent pixels in the test pattern. The method adjusts an operation of the plurality of ejectors to normalize heights of layers of material formed by the plurality of ejectors based on the measured heights for the groups of adjacent pixels.

Abstract: A three-dimensional object printer is configured to enable the density of material ejected by at least one printhead onto a rotating platen near its circumferential edge to be approximately the same as the density of the material ejected onto the rotating platen near the center of the platen.

Abstract: An additive manufacturing system operates at least one ejector and an extruder to form three-dimensional objects with photopolymer material and thermoplastic material. The system operates to deposit the two materials in a layer-by-layer manner. The photopolymer material provides high resolution finishes on the objects and the thermoplastic material enables strong and stable formation of internal portions of the objects.

Abstract: A method of manufacturing a three-dimensional object comprises: selecting a first ejector in a plurality of ejectors of a three-dimensional object printer with reference to a hardness identifier, the first ejector configured to eject a first material; selecting a second ejector in the plurality of ejectors with reference to a color identifier, the second ejector configured to eject a second material having a hardness that is different than a hardness of the first material; operating the first ejector to eject the first material toward a platen to form an inner portion of the object with the first material; and operating the second ejector to eject the second material toward the platen to form an outer layer of the object with the second material, the outer layer of the object surrounding at least a portion of the inner portion of the object.

Abstract: A method of manufacturing a three-dimensional object compensates for different rates of shrinkage during curing of dissimilar materials. The compensation is achieved by ejecting the different materials with reference to the shrinkage rates of the materials to enable the materials to be at approximately a same height following curing of the materials.

Abstract: A three-dimensional object printer ejects drops of a build material from a plurality of ejectors in a first printhead to form an object on a first region of a member and ejects drops of a support material from a plurality of ejectors in a second printhead to support the object on the first region of the member. The second printhead ejects drops of the support material onto a second region of the member that is separate from the first region to form a substrate layer. The first printhead ejects drops of the build material onto the substrate layer to form a printed test pattern. An image sensor generates image data of the printed test pattern to identify an inoperable ejector in the first printhead.

Abstract: A method of manufacturing a three-dimensional object comprises: selecting a first ejector in a plurality of ejectors of a three-dimensional object printer with reference to a hardness identifier, the first ejector configured to eject a first material; selecting a second ejector in the plurality of ejectors with reference to a color identifier, the second ejector configured to eject a second material having a hardness that is different than a hardness of the first material; operating the first ejector to eject the first material toward a platen to form an inner portion of the object with the first material; and operating the second ejector to eject the second material toward the platen to form an outer layer of the object with the second material, the outer layer of the object surrounding at least a portion of the inner portion of the object.

Abstract: A system for printing at least one stretchable ink on a thermoformable substrate having a first surface and a second surface opposite the first surface, the system 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 of the first surface to enhance wetting and adhesion of the at least one stretchable ink to the thermoformable substrate, at least one first full width printhead array arranged to deposit a first portion of the at least one stretchable ink on the first surface of the thermoformable substrate, at least one second full width printhead array arranged to deposit a second portion of the at least one stretchable ink on the first surface of the thermoformable substrate, at least one radiation pinning device positioned proximate the second surface and arranged to partially cure the first portion of the at least one stretchable ink on the thermoformable substrate p

Abstract: A method for compensating for inoperative ejectors in a three-dimensional object printer has been developed. A printer detects an inoperative ejector in a printhead. The printer identifies functional ejectors that print at locations adjacent to locations where the inoperative ejector fails to print a drop. The printer modifies firing signals for the functional ejectors so those ejectors print drops having an increased drop volume at the locations adjacent to locations where the inoperative ejector fails to print a drop. The printer prints a first layer of material drops using the modified firing signals. The printer advances the printhead in the cross-process direction between layers so that locations where the inoperative ejector fails do print a drop do not coincide between layers.

Abstract: A printer is configured to continue printing during maintenance of at least one printhead in the printer. The printer includes a plurality of printheads that each eject drops that overlap with adjacent drops ejected by another printhead. At least one printhead is selected for maintenance, moved to a position for performance of a maintenance operation, and returned to the position from which it was originally moved, while the remaining printheads continue to eject drops. The newly serviced printhead is returned to the position from which it was originally moved.

Abstract: A system for printing at least one stretchable ink on a thermoformable substrate having a first surface and a second surface opposite the first surface, the system 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 of the first surface to enhance wetting and adhesion of the at least one stretchable ink to the thermoformable substrate, at least one first full width printhead array arranged to deposit a first portion of the at least one stretchable ink on the first surface of the thermoformable substrate, at least one second full width printhead array arranged to deposit a second portion of the at least one stretchable ink on the first surface of the thermoformable substrate, at least one radiation pinning device positioned proximate the first surface and arranged to partially cure the first portion of the at least one stretchable ink on the thermoformable substrate pr

Abstract: An additive manufacturing system operates at least one ejector and an extruder to form three-dimensional objects with photopolymer material and thermoplastic material. The system operates to deposit the two materials in a layer-by-layer manner. The photopolymer material provides high resolution finishes on the objects and the thermoplastic material enables strong and stable formation of internal portions of the objects.

Abstract: A three-dimensional object printer is configured to enable the density of material ejected by at least one printhead onto a rotating platen near its circumferential edge to be approximately the same as the density of the material ejected onto the rotating platen near the center of the platen.

Abstract: A three-dimensional object printer is configured to enable the density of material ejected by at least one printhead onto a rotating platen near its circumferential edge to be approximately the same as the density of the material ejected onto the rotating platen near the center of the platen.

Abstract: A method of manufacturing a three-dimensional object operates components in an additive manufacturing system with reference to quantifications identified for properties of different materials in a same layer. The method enables the layer to be formed with compensation for the differences in the quantifications of the properties of the two materials.

Abstract: A controller in a printer operates one or more printheads in the printer with reference to a predetermined height of material above a surface of a member and a height of a top layer of material above the surface of the member. The height of the top layer is identified with reference to a first sensor that generates data corresponding to a height of a face of one of the printheads above the surface of the member and a second sensor that generates data corresponding to a distance between the face of one of the printheads and the top layer of material.

Abstract: A sacrificial coating on an intermediate transfer member of an aqueous ink imaging system is disclosed. The sacrificial coating is made from ingredients comprising: a waxy starch; at least one polycarboxylic acid cross-linking agent; at least one hygroscopic material; and at least one surfactant.

Abstract: A printer forms a three-dimensional object on a rotating substrate. The printer includes a frame that supports a cylindrical member and at least one printhead such that the first printhead is positioned to eject material onto an outer surface of the cylindrical member. The frame is movable between a first position that rotatably supports the cylindrical member and a second position that enables transfer of the cylindrical member to and from the frame. A controller operates the printhead to eject material onto the rotating cylindrical member to form the object. The controller interpolates a periodic signal generated from a position encoder to adjust the operation of the printhead based on the rotational position and velocity of the cylindrical member. The controller operates a driver to move the frame to the second position to enable removal of the cylindrical member from the printer.