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 process and device for removing a solid ink mask printed onto a substrate is disclosed. The substrate is bent around a bar set perpendicular to the substrate, causing the mask to flake off the substrate. The process permits fast removal of solid ink masks.

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 printer forms a three-dimensional object on a rotating substrate. The printer includes a first driver to rotate the substrate past at least one printhead at a predetermined velocity and a controller to operate the printhead to eject material onto the substrate to form the object. A second driver is operated to move the position of the printhead perpendicular to the substrate to maintain a predetermined gap between the printhead and the layer of material most distant from the substrate. The second driver is further operable to move the position of the printhead parallel to the substrate to adjust a resolution of the ejected material. The controller interpolates an alternating signal generated from a position encoder to adjust the operation of the printhead based on the rotational position and velocity of the substrate.

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 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: An aqueous inkjet printer is configured to reduce condensation of vapor on printhead faces. The printer includes air directing members between adjacent printheads in a process direction and an air mover pneumatically connected to the air directing members. The air mover is operated selectively to remove vapor in the air between adjacent printheads as an ink image is formed on an image receiving surface moves past the adjacent printheads.

Abstract: An aqueous inkjet printer is configured to reduce condensation of vapor on printhead faces. The printer includes air directing members between adjacent printheads in a process direction and an air mover pneumatically connected to the air directing members. The air mover is operated selectively to remove vapor in the air between adjacent printheads as an ink image is formed on an image receiving surface moves past the adjacent printheads.

Abstract: A process and device for removing a solid ink mask printed onto a substrate is disclosed. The substrate is bent around a bar set perpendicular to the substrate, causing the mask to flake off the substrate. The process permits fast removal of solid ink masks.

Abstract: A printer comprises a plurality of printheads, at least one auxiliary dryer positioned immediately adjacent the plurality of printheads and configured to control spread of ink drops ejected by the plurality of printheads, a main dryer positioned to dry ink on the media after the media has passed the at least one auxiliary dryer, at least one actuator to drive media transport and move media past each of these components, and a controller. The power of the main dryer is higher than the power of the auxiliary dryer. The controller is operatively connected to each of the components and is configured to control the operation of the at least one auxiliary dryer with reference to the type of media being printed and the type of ink being ejected. A method for operating the printer is also disclosed.

Abstract: A process of patterning a conductive film. The process comprises providing a substrate comprising a conductive film positioned on a surface of the substrate. A hydrophilic primer layer is coated on the conductive film. Droplets of etchant are ejected from an inkjet printer in an imagewise pattern onto the primer layer to pattern the conductive film. The primer layer is removed from the substrate.

Abstract: A printer uses closed loop control to keep material drops ejected by a printhead within a predetermined range. The printer forms at least two objects on a support member and then operates a specular sensor array to obtain image data of the two objects on the support member. The two objects have different predetermined heights to enable a controller in the printer to identify the mass or volume of the material drops forming the objects to adjust operational parameters of the printer to maintain the mass or volume of the material drops in the predetermined range.

Abstract: A printer comprises an applicator, a primer dryer, a plurality of printheads, an auxiliary dryer configured to at least partially dry ink ejected by the plurality of printheads, a main dryer configured to dry ink ejected by the plurality of printheads, a media transport configured to move media past each of these components, and a controller. The controller operates the applicator to apply a predetermined amount of primer to a surface of media, the primer dryer at a predetermined temperature to dry the primer, the plurality of printheads to eject ink to the surface of media, the auxiliary dryer at a predetermined temperature to at least partially dry the ink ejected by the printheads to control the spread of ink, and the main dryer to dry the ink image. The controller uses a plurality of set points corresponding to printing process parameters identified for each print job.

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 compensates for printing errors occurring during production of the layers for the formation of an object in a three-dimensional printer. The printer includes an optical sensor that generates data corresponding to edges of each layer of the object after each layer is printed. Differences between the raster data used to eject the material to form a layer and the data received from the optical sensor are used to modify the raster data that operates a printhead to form a next layer in the object.

Abstract: An indirect printing process comprises providing an inkjet printing apparatus comprising an intermediate transfer member. A wet sacrificial coating composition is deposited onto the intermediate transfer member. The wet sacrificial coating composition is made from ingredients comprising: a waxy starch; at least one hygroscopic material; at least one surfactant; and a liquid carrier. The wet sacrificial coating composition is dried to form a dry sacrificial coating. Droplets of ink are ejected in an imagewise pattern onto the dry sacrificial coating. The ink is at least partially dried to form a substantially dry ink pattern. Both the substantially dry ink pattern and the sacrificial coating are transferred from the intermediate transfer member to a final substrate. At least one cross-linking agent is applied to cross-link the sacrificial coating.

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 ink includes a C10 to C26 fatty acid and a microcrystalline wax, the ink exhibiting greater scratch resistance than a conventional ink as measured by scratch and fold testing.

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 printer compensates for printing errors occurring during production of the layers for the formation of an object in a three-dimensional printer. The printer includes an optical sensor that generates data corresponding to edges of each layer of the object after each layer is printed. Differences between the raster data used to eject the material to form a layer and the data received from the optical sensor are used to modify the raster data that operates a printhead to form a next layer in the object.