Abstract: A collection of camera-based monitoring sub-systems can be added to a composite-based additive manufacturing (CBAM) system to autonomously inspect the integrity of each layer and remediate issues in real time. Cameras are located at various stations throughout the process. Resulting images are analyzed to see if processed pages are within tolerance based on comparison with models. Cameras can be placed at the print platen, on a rear conveyor that conveys powdered pages to the stacker and in the stacker itself to make sure pages are stacked and aligned properly. The present invention provides quality assurance and quality control to validate the build process at the layer level. This reduces the amount of post-build labor to perform, and since it shows data internal to the part, it dramatically reduces the amount of destructive testing required.

Abstract: A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

Abstract: A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material comprising engineered powder that 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. The powder may be emulsion aggregation powder, chemically-produced toner powder, or a combination. It may be a thermoplastic or thermosettable polymer and may include nylon, elastomers, polyolefins, polyethylene, polyether ether ketone, polyimide, polyetherimide, polyphenylene sulfide, polystyrene, polypropylene, polymethyl methacrylate, and polyaryletherketone, or a combination. The powder particles may have a pre-specified controlled shape and/or a non-homogenous composition. Surface treatments and/or additives may be used to control powder flow and charge distribution. Each substrate layer may be a sheet-like structure comprising fibers held together by binder.

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 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

Abstract: A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

Abstract: A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

Abstract: In an illustrative implementation of this invention, a 3D object comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers.

Abstract: A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

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: A distributed heterogeneous or homogeneous file storage system divides logical responsibility for data from actual control of the data by using separate file and storage managers. Each file manager provides access to stored files and stores metadata associated with each of the files for which it is responsible. A file manager control component allocates responsibilities among file managers, assigns management responsibilities for individual files, and maintains a record of which files are assigned to each manager. Each storage manager is responsible for managing storage of files on data storage devices and maintains a record of the location of each stored file. A storage manager control component allocates responsibilities among storage managers, assigns responsibilities for individual files, and maintains a record of which files and storage devices are assigned to each manager.

Abstract: A 3D object (the “New Object”) is fabricated layer by layer by 3D printing. The shape and relative dimensions of the various parts of the New Object match that of another 3D object (the “Target Object”). In addition, the exterior of the New Object appears to be a photographic likeness of the Target Object. The “photographic” likeness is created by variations in visual characteristics of materials in the layers comprising the New Object, and in particular by variations at or near the surface of the New Object. Thus, the photographic likeness is an integral part of these layers comprising the New Object. An object is scanned, from which a texture map is obtained. A CAD model is sliced into slices (bit maps files) which are then colored by a program with the boundary to match the color or gray scale to color the appropriate pixels, derived from the texture map.

Abstract: A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

Abstract: A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

Abstract: A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

Abstract: A tow stabilization method includes applying liquid to a tow having fibers arranged into a non-stabilized spread-out fiber web, applying powder to the web to adhere the powder where liquid was applied, removing powder from where it did not adhere, and fusing the powder remaining on the web to stabilize the fiber arrangement. The liquid may be volatile. The step of fusing may include heating the fiber web. The liquid and/or powder may be selectively applied. Selective application of powder may be used without application of liquid or powder removal. A tow stabilization apparatus includes a liquid applicator, powder applicator, powder remover, and powder fuser. The liquid applicator may include spray nozzles, applicators based on miniature solenoid valves, inkjet printing heads, and roll applicators. The powder remover may include rollers, air blasters, vibrators, sound wave generators, and vacuums. The powder fuser may include heat applicators and chemical reaction initiators.

Abstract: A 3D object (the “New Object”) is fabricated layer by layer by 3D printing. The shape and relative dimensions of the various parts of the New Object match that of another 3D object (the “Target Object”). In addition, the exterior of the New Object appears to be a photographic likeness of the Target Object. The “photographic” likeness is created by variations in visual characteristics of materials in the layers comprising the New Object, and in particular by variations at or near the surface of the New Object. Thus, the photographic likeness is an integral part of these layers comprising the New Object. An object is scanned, from which a texture map is obtained. A CAD model is sliced into slices (bit maps files) which are then colored by a program with the boundary to match the color or gray scale to color the appropriate pixels, derived from the texture map.

Abstract: Cement or other liquid-like material fills the hollow tubes of a machine tool under construction. The machine tool structures are held rigidly against a fixture while the substance dries. The machine tool so constructed is relatively lightweight and rigid, and obviates the need for precision machining of large portions of the apparatus.

Abstract: In an exemplary embodiment of this invention, corrugated board is folded into a building system. The building system comprises a plurality of blocks and connectors. The blocks are rectangular cuboid in shape. The bottom and top sides of the blocks have rectangular arrays of holes. The blocks may be releasably connected by aligning the top holes of one block with the bottom holes of another block, and then inserting connectors into the aligned pairs of holes, one connector per aligned paid of holes. The ends of the connectors that are inserted are circular or equiangular polygonal in shape. In some embodiments, compression is used to releasably hold the connectors in place.