Abstract: A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material. Each substrate layer is a sheet-like structure that comprises fibers held together by a sodium silicate binder. The substrate layer material may be non-woven or woven. The substrate layer may be a non-woven fiber veil bound by a sodium silicate binder. The fibers may optionally include carbon fibers, ceramic fibers, polymer fibers, glass fibers, metal fibers, or a combination thereof.

Abstract: A double dump valve apparatus has the doors flap open in opposite horizontal orientations and directions.

Abstract: A platen for a 3D printer apparatus contains tab pairs for the winding of a single wire to form the platen surface after being wound back and forth across its length. Punch backs for hole punching onto such a sheet exist on aluminum blocks that secure rails between which the platen is assembled onto the printer table top.

Abstract: A platen for a 3D printer apparatus contains tab pairs for the winding of a single wire to form the platen surface after being wound back and forth across its length. Punch backs for hole punching onto such a sheet exist on aluminum blocks that secure rails between which the platen is assembled onto the printer table top.

Abstract: An apparatus and method for the automated manufacturing of three-dimensional (3D) composite-based objects is disclosed. The apparatus comprises a material feeder, a printer, a powder system, a transfer system, and optionally a fuser. The method comprises inserting a stack of substrate sheets into a material feeder, transferring a sheet of the stack from the material feeder to a printer, depositing fluid on the single sheet while the sheet rests on a printer platen, transferring the sheet from the printer to a powder system, depositing powder onto the single sheet such that the powder adheres to the areas of the sheet onto which the printer has deposited fluid, removing any powder that did not adhere to the sheet, optionally melting the powder on the substrate, and repeating the steps for as many additional sheets as required for making a specified 3D object.

Abstract: A stacker for a 3D printer apparatus contains a positioning conveyor and a support plate hinged to drop on a signal, whereupon a push plate will push a printed and powdered sheet downward and onto registration pins, to form a stacked register of such sheets.

Abstract: A felt gripper head contains two regions of felt material each on plates that slide and form a slight angle with respect to each other during engagement with a fibrous substrate material.

Abstract: An apparatus and method for the automated manufacturing of three-dimensional (3D) composite-based objects is disclosed. The apparatus comprises a material feeder, a printer, a powder system, a transfer system, and optionally a fuser. The method comprises inserting a stack of substrate sheets into a material feeder, transferring a sheet of the stack from the material feeder to a printer, depositing fluid on the single sheet while the sheet rests on a printer platen, transferring the sheet from the printer to a powder system, depositing powder onto the single sheet such that the powder adheres to the areas of the sheet onto which the printer has deposited fluid, removing any powder that did not adhere to the sheet, optionally melting the powder on the substrate, and repeating the steps for as many additional sheets as required for making a specified 3D object.

Abstract: A powder refill system for a CBAM process that makes changing a powder container simple and maintains the smallest possible distribution change during the print process. The system automates a constantly low trough powder level during a print and reduces the number of times the powder is recirculated. The system uses a sensor to sense the amount of powder in a tray and a compressed air powder application system to force powder into the system. Powder enters the system from a powder bottle mounted upside-down on a plate with an orifice and mixing chamber and a stainless-steel “aeration stone” This is a fitting with porous walls, where porosity is finer than most of particulate matter of the powder being used. Air can enter through the fitting, broken down into microscopic streams, but powder cannot enter back into the air supplying line. The powder aerosol is then used in the printing/flooding process. A mounting plate allows easy replacement of the powder bottle.

Abstract: A three-dimensional object comprises substantially planar or flat substrate layers that are folded and stacked in a predetermined order and infiltrated by a hardened material. The object is fabricated by positioning powder on all or part of multiple substrate layers. On each layer, the powder is selectively deposited in a pattern that corresponds to tiles that each have a slice of the object. For each slice, powder is deposited in positions that correspond to positions in the slice where the object exists, and not deposited where the object does not exist. The tiles of each substrate layer are folded and aligned in a predetermined order. Multiple folded substrate layers mat be combined into a single stack. The powder is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers.

Abstract: Apparatus, systems and processes embodying supporting material feedstock for making a support structure for overhangs in a three-dimensional object via a multi-nozzle fused deposition modeling printer, wherein the supporting material is polylactic acid, which is soluble in solution causing base-catalyzed alcoholosis.

Abstract: A method of residual ink removal in an ink-dependent 3-D printing process includes pre-heating a build block to an evaporation temperature. This is preferably done after stacking and before compression. Later compression will then involve a higher temperature to allow fusing of thermoplastic material in the build block, but without residual ink.

Abstract: A method and apparatus for resistive heating usable in composite-based additive manufacturing is disclosed. The method includes providing a prepared stack of substrate sheets, placing the stack between electrode assemblies of a compression device, applying a current to thereby heat the stack to a final temperature to liquefy applied powder, compressing the stack to a final height, cooling the stack, and removing the cooled, compressed stack from the compression device. The apparatus comprises at least two plates, a power supply for providing current, a first electrode assembly and a second electrode assembly.

Abstract: A double dump valve apparatus possesses a space saving arrangement by having the doors flap open in opposite horizontal orientations and directions.

Abstract: A system and method for lifting substrate sheets off of a stack of porous sheets one at a time, even though the sheets tend to stick together. A felt tamp is lowered onto the stack of sheets, and as the tamp is raised, a set of edge flickers create a downward force on the corners of the top sheet. This causes the edges of the top sheet to bend downward slightly just enough to pry the second sheet loose from the top sheet. The tamp can then be further raised with only the top sheet adhering to the felt, and the lifted sheet can be deposited at the next station in the process. Periodically, a brush is used to renew the surface of the felt to prevent matting of the felt fibers.

Abstract: A powder refill system for a CBAM process that makes changing a powder container simple and maintains the smallest possible distribution change during the print process. The system automates a constantly low trough powder level during a print and reduces the number of times the powder is recirculated. The system uses a sensor to sense the amount of powder in a tray and a compressed air powder application system to force powder into the system. Powder enters the system from a powder bottle mounted upside-down on a plate with an orifice and mixing chamber and a stainless-steel “aeration stone” This is a fitting with porous walls, where porosity is finer than most of particulate matter of the powder being used. Air can enter through the fitting, broken down into microscopic streams, but powder cannot enter back into the air supplying line. The powder aerosol is then used in the printing/flooding process. A mounting plate allows easy replacement of the powder bottle.

Abstract: A bulk ink bag system in a composite-based additive manufacturing process (CBAM) keeps the inkjet heads (cartridges) on printers filled to the proper level of fluid at all times while the process runs. The system includes gravity fed fluid delivery without requiring pumps; is simple to connect and disconnect to system plumbing; has the ability to change ink bags without interrupting the print job or introducing air bubbles into the ink supply; and has the ability to disconnect partially used bags and reconnect them later.

Abstract: An additive manufacturing method and apparatus is described for the printing of three-dimensional (3D) objects. The approach is based on a composite-based additive manufacturing process, except it uses commercial printing methods to achieve even higher speed and throughput. By using the invention, a prototyping and/or production process may be completed in hours rather than months, and the risks and problems of molds is eliminated. There is substantial improvement in the number and type of geometries that can be produced compared to injection molding, and the range of materials is enlarged as are the material properties. The method involves printing a substrate having at least one sheet using a printing technology, and stacking or folding the at least one sheet to form multiple layers consistent with that formed by a 3D model. The printing step is done using a printing technology such as flexography, lithography, offset, gravure, waterless printing, and silkscreen.

Abstract: An apparatus and method for the automated manufacturing of three-dimensional (3D) composite-based objects is disclosed. The apparatus comprises a material feeder, a printer, a powder system, a transfer system, and optionally a fuser. The method comprises inserting a stack of substrate sheets into a material feeder, transferring a sheet of the stack from the material feeder to a printer, depositing fluid on the single sheet while the sheet rests on a printer platen, transferring the sheet from the printer to a powder system, depositing powder onto the single sheet such that the powder adheres to the areas of the sheet onto which the printer has deposited fluid, removing any powder that did not adhere to the sheet, optionally melting the powder on the substrate, and repeating the steps for as many additional sheets as required for making a specified 3D object.

Abstract: A method and powder system component of an apparatus for use in a printing process is disclosed, and for removing and recycling excess powder. The powder system results in a cutoff point of 3 microns rather than 50 microns of previous systems. The apparatus comprises a powder applicator, a powder remover, a helical cyclone, a powder collector, and two valves that alternately open and close. The two-valve system prevents air backflow. The powder is processed through the two-valve system. The method comprises: valve 1 is closed and powder accumulates; valve 2 is closed also; after valve 1 opens, powder goes through (there is no air backflow), then valve 1 closes; then valve 2 opens and allows powder onto a powder applicator; then valve 2 closes; then the cycle starts again.