Abstract: A system for producing three-dimensional objects forms fluid paths within the support structure to facilitate the removal of the support structure following manufacture of the object. The system includes a first ejector configured to eject a first material towards a platen to form an object, a second ejector configured to eject a second material towards the platen to form support for portions of the object, at least one portion of the support having a body with at least one fluid path that connects at least one opening in the body to at least one other opening in the body, and a fluid source that connects to the at least one fluid path of the support to enable fluid to flow through the at least one fluid path to remove at least an inner portion of the support from the object.

Abstract: A method of manufacturing a three-dimensional object is disclosed. The method includes operating a first ejector of a three-dimensional object printer to eject a first material towards a platen to form an object. The method further includes operating a second ejector of the three-dimensional object printer to eject a second material towards the platen to form support for portions of the object, the support being configured to provide support for portions of the object during the operation of the first ejector to form the object, at least one portion of the support having a body with at least one fluid path that connects at least one opening in the body to at least one other opening in the body. The method further includes connecting a fluid source to the at least one fluid path of the support to enable fluid to flow through the at least one fluid path to remove at least an inner portion the support from the object.

Abstract: A system uses microwave energy to remove support material from a three-dimensional printed object with reduced risk of damage to the object. The system includes a microwave source, a three port device, a susceptor, a temperature sensor, and a controller. The controller operates the microwave source to direct microwave energy into a first port of the three port device, which emits the microwave at a second port of the three port device to irradiate the three-dimensional object and melt the support material. Reflected microwave increases as the amount of support material contacting the object is reduced and enters the second port of the three port device, which directs the reflected energy to the susceptor coupled to a third port of the three port device. The controller monitors the signal generated by the temperature sensor and deactivates the microwave source in response to a predetermined condition being reached.

Abstract: A system for manufacturing a three-dimensional object facilitates the removal of support material from the object. The system includes a controller configured to move a platen to position the object at a position opposite a microwave radiator and then operate the microwave radiator to change the phase of the support material from solid to liquid. The controller either monitors the expiration of a predetermined time period or a temperature of the object to determine when the microwave radiator operation is terminated. The microwave radiation does not damage the object because the support material has a dielectric loss factor that is greater than the dielectric loss factor of the object.

Abstract: A sheet stacking system is disclosed that has improved tolerance for sheets that are not flat. Successive sheets are aligned onto a stack by a plurality of registration belts. The heights of the pivoting registration belts are compared with one another to determine the unevenness of the top of the stack. This unevenness is represented by the difference between the heights of the highest and lowest registration belt ?stack-height and is monitored to quantify the planarity of the top of the stack. When the unevenness (?stack-height) exceeds a threshold, the system switches to a modified method to control the elevation of the stack. This method may include stopping the machine from stacking before the unevenness is too large for the registration belts to uniformly drive sheets. This invention prevents the stacker from attempting to stack when sheets are expected to skew thereby preventing jams and unusable stacks.

Abstract: A three-dimensional object printer comprises a conveyor having a surface configured to convey a three-dimensional object in a first direction; a leveling assembly configured to level a surface of the three-dimensional object as the conveyer conveys the three-dimensional object in the first direction, the leveling assembly comprising (i) a member, (ii) a roller connected to the member having a cylindrical shape, the roller having an outer surface that moves upon the surface of the three-dimensional object to level a surface of the three-dimensional object, and (iii) an actuator arranged near the member, the actuator being configured to mechanically interact with the member to move the roller with respect to the planar surface of the conveyer; and a controller configured to, as the outer surface of the roller moves upon the surface of the three-dimensional object, operate the actuator to move the roller with respect the conveyer.

Abstract: A method of manufacturing a three-dimensional object facilitates the removal of support material from the object. The method includes moving the object to a position opposite a microwave radiator and operating the microwave radiator to change the phase of the support material from solid to liquid. A controller either monitors the expiration of a predetermined time period or a temperature of the object to determine when the microwave radiator operation is terminated. The microwave radiation does not damage the object because the support material has a dielectric loss factor that is greater than the dielectric loss factor of the object.

Abstract: A system treats uneven surfaces of additive manufactured objects to improve the transparency and glossiness of the surfaces. The system operates a sprayer to apply fluid material used to form the uneven surface to the uneven surface to smooth the surface or the system operates an actuator to dip the additive manufactured object into a bath of fluid material that is the same as the material used to form the uneven surface to smooth the surface. A heater is provided to dry non-UV curable material applied to the uneven surface and a source of UV radiation is provided to cure UV curable material applied to the uneven surface.

Abstract: A three-dimensional object printer has a platen that is configured to facilitate the release of objects formed on the platen. The platen includes a first layer and second layer, the first layer having a coefficient of thermal expansion that is different than a coefficient of thermal expansion of the second layer. A controller in the printer is configured to operate at least one ejector in an ejector head to form a three-dimensional object on the surface of the platen with reference to digital image data and, upon completion of the object, to operate a temperature control device operatively connected to the platen to bend the platen by changing the temperature of the platen and releasing a three-dimensional object from the platen.

Abstract: Methods and systems related to the three-dimensional (3D) printing of build structures including a plurality of 3D objects embedded within a support matrix are provided.

Abstract: A three-dimensionally printed object includes build portions formed with a build material, first support portions formed with a first support material, and second portions formed with a second support material that is different than the first support material. The first and second support portions are arranged with the build portions such that the build portions are supported and protected during fabrication of the object. The arrangement is optimized to minimize a time period for removing the first and second support materials from the object and releasing the build portions. A method of producing the object includes operating ejectors of a three-dimensional object printer to form the build portion, first support portions, and the second support portions. The portions are formed with reference to the arrangement.

Abstract: A three-dimensional object printer comprises a platen, an ejector head having a plurality of ejectors configured to eject drops of material toward the platen, a sensor configured to measure heights of drops of material ejected onto the platen, and a controller operatively connected to the sensor and the ejector head. The controller is configured to operate the plurality of ejectors to eject drops of material toward the platen to form a first layer of material upon the platen; operate the sensor to measure a height profile of the first layer of material; and operate the plurality of ejectors to eject drops of material toward the platen to form a second layer of material upon the first layer of material with reference to the measured height profile.

Abstract: A three-dimensional object printer comprises a conveyor having a surface configured to convey a three-dimensional object in a first direction; and a leveling assembly configured to level a surface of the three-dimensional object as the conveyer conveys the three-dimensional object in the first direction, the leveling assembly comprising (i) a roller having a cylindrical shape, the roller having an outer surface that moves upon the surface of the three-dimensional object to level the surface of the three-dimensional object; and (ii) a guide device arranged between the roller and the planar surface of the conveyer, the device being configured to mechanically interact with the roller to maintain a constant distance between the outer surface of the roller and the planar surface of the conveyer.

Abstract: A three-dimensional object printer comprises a conveyor having a surface configured to convey a three-dimensional object in a first direction; a leveling assembly configured to level a surface of the three-dimensional object as the conveyer conveys the three-dimensional object in the first direction, the leveling assembly comprising (i) a member, (ii) a roller connected to the member having a cylindrical shape, the roller having an outer surface that moves upon the surface of the three-dimensional object to level a surface of the three-dimensional object, and (iii) an actuator arranged near the member, the actuator being configured to mechanically interact with the member to move the roller with respect to the planar surface of the conveyer; and a controller configured to, as the outer surface of the roller moves upon the surface of the three-dimensional object, operate the actuator to move the roller with respect the conveyer.

Abstract: A method of operating a cleaning system removes support material from parts made by a three-dimensional printer. The method operates the cleaning system to correlate data for features on a part located within a receptacle with structural data in a file used by the three-dimensional printer to fabricate the part. The method then operates one or more actuators to locate a fluid directing nozzle pneumatically connected to a pressurized fluid source opposite areas containing support material and operates the pressurized fluid source to enable pressurized fluid to be directed by the fluid directing nozzle at the support material. The method includes generating image data of the cleaned areas with an image sensor so the removal of the support material can be confirmed, and if an area is not sufficiently cleaned, the cleaning operation can be repeated.

Abstract: A method of manufacturing a three-dimensional object facilitates the removal of support material from the object. The method includes moving the object to a position opposite a microwave radiator and operating the microwave radiator to change the phase of the support material from solid to liquid. A controller either monitors the expiration of a predetermined time period or a temperature of the object to determine when the microwave radiator operation is terminated. The microwave radiation does not damage the object because the support material has a dielectric loss factor that is greater than the dielectric loss factor of the object.

Abstract: A system uses microwave energy to remove support material from a three-dimensional printed object with reduced risk of damage to the object. The system includes a microwave source, a three port device, a susceptor, a temperature sensor, and a controller. The controller operates the microwave source to direct microwave energy into a first port of the three port device, which emits the microwave at a second port of the three port device to irradiate the three-dimensional object and melt the support material. Reflected microwave increases as the amount of support material contacting the object is reduced and enters the second port of the three port device, which directs the reflected energy to the susceptor coupled to a third port of the three port device. The controller monitors the signal generated by the temperature sensor and deactivates the microwave source in response to a predetermined condition being reached.

Abstract: A method of manufacturing a three-dimensional object is disclosed. The method includes operating a first ejector of a three-dimensional object printer to eject a first material towards a platen to form an object. The method further includes operating a second ejector of the three-dimensional object printer to eject a second material towards the platen to form support for portions of the object, the support being configured to provide support for portions of the object during the operation of the first ejector to form the object, at least one portion of the support having a body with at least one fluid path that connects at least one opening in the body to at least one other opening in the body. The method further includes connecting a fluid source to the at least one fluid path of the support to enable fluid to flow through the at least one fluid path to remove at least an inner portion the support from the object.

Abstract: A method of manufacturing a three-dimensional object facilitates the removal of support material from the object. The method includes forming at least a portion of a support for the object with support material containing nanoparticles of a material that readily converts microwave energy into heat. The object and support are moved to a position opposite a microwave radiator and the microwave radiator is operated to begin a change of the phase of the portion of the support material containing the nanoparticles before beginning a change of the phase of a portion of the support made from the support material alone. A controller either monitors the expiration of a predetermined time period or a temperature of the object to determine when the microwave radiator operation is terminated.

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.