Patents by Inventor Chris Counts

Chris Counts has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 12036727
    Abstract: A method for making a three-dimensional (3D) part with an electrostatographic based additive manufacturing system includes developing a first layer of a powder material using at least one electrostatographic engine, supporting the developed first layer on a transfer medium, adjusting a first layer thermal profile of the developed first layer with a first thermal flux device, adding thermal energy to a part thermal profile that includes a bonding region of previously accumulated layers of the 3D part, transfusing the developed first layer on the bonding region of the previously accumulated layers of the 3D part, and removing thermal energy from the part thermal profile. A transfusion temperature at a start of the transfusing step can be equal to or greater than a transfusion threshold temperature, where the transfusion temperature is an average of the first layer thermal profile and the part thermal profile in the bonding region.
    Type: Grant
    Filed: September 5, 2019
    Date of Patent: July 16, 2024
    Assignee: Evolve Additive Solutions, Inc.
    Inventors: Arun Chowdry, James W. Comb, Chris Counts, J. Samuel Batchelder
  • Patent number: 11904531
    Abstract: Disclosed are selective deposition based additive manufacturing systems (10) and methods for printing a 3D part. Layers of a powder material (22) are developed using one or more electrostatography-based engines (12). The layers (22) are transferred for deposition on a part build surface. For each of the layers (22), the part build surface is heated to a temperature within a range between a flowable temperature and a thermal oxidation threshold to form a flowable part build surface, and the developed layer (22) is pressed into contact with the flowable build surface (88) to heat the developed layers (22) to a flowable state and form a new part build surface (88) which is fully consolidated. The new part build surface (88) is then cooled to remove the heat energy added during heating step before repeating the steps for the next developed layer.
    Type: Grant
    Filed: December 28, 2018
    Date of Patent: February 20, 2024
    Inventors: Chris Counts, J. Samuel Batchelder
  • Publication number: 20200338813
    Abstract: Disclosed are selective deposition based additive manufacturing systems (10) and methods for printing a 3D part. Layers of a powder material (22) are developed using one or more electrostatography-based engines (12). The layers (22) are transferred for deposition on a part build surface. For each of the layers (22), the part build surface is heated to a temperature within a range between a flowable temperature and a thermal oxidation threshold to form a flowable part build surface, and the developed layer (22) is pressed into contact with the flowable build surface (88) to heat the developed layers (22) to a flowable state and form a new part build surface (88) which is fully consolidated. The new part build surface (88) is then cooled to remove the heat energy added during heating step before repeating the steps for the next developed layer.
    Type: Application
    Filed: December 29, 2017
    Publication date: October 29, 2020
    Inventors: Chris Counts, J. Samuel Batchelder
  • Publication number: 20200338825
    Abstract: A selective-deposition-based additive manufacturing system (10) includes a transfer medium (24) configured to receive the layers (22) from an imaging engine (12), a heater (72) configured to heat the layers (22) on the transfer medium (24), and a layer transfusion assembly (20) that includes a build platform (28), and is configured to transfuse the heated layers (22) onto the build platform (28) in a layer-by-layer manner to print a three-dimensional part (22). The transfusion assembly (20) includes a nip roller (320) configured to deform when transfusing the heated imaged layers (22) to reduce deformation of the layers (22).
    Type: Application
    Filed: December 28, 2017
    Publication date: October 29, 2020
    Inventors: James W. Comb, Chris Counts
  • Publication number: 20200307087
    Abstract: Embodiments herein relate to substrates for use in a selective toner electrophotographic process (STEP) additive manufacturing system. The substrates include a build platform for use in STEP additive manufacturing system, the build platform comprising a build substrate for receiving a build material deposited by a STEP process; wherein the platform has selected thermal properties, such as within 30 percent of the build material to be deposited onto the substrate.
    Type: Application
    Filed: February 20, 2020
    Publication date: October 1, 2020
    Inventors: Chris Counts, J. Samuel Batchelder
  • Publication number: 20200079008
    Abstract: A method for making a three-dimensional (3D) part with an electrostatographic based additive manufacturing system includes developing a first layer of a powder material using at least one electrostatographic engine, supporting the developed first layer on a transfer medium, adjusting a first layer thermal profile of the developed first layer with a first thermal flux device, adding thermal energy to a part thermal profile that includes a bonding region of previously accumulated layers of the 3D part, transfusing the developed first layer on the bonding region of the previously accumulated layers of the 3D part, and removing thermal energy from the part thermal profile. A transfusion temperature at a start of the transfusing step can be equal to or greater than a transfusion threshold temperature, where the transfusion temperature is an average of the first layer thermal profile and the part thermal profile in the bonding region.
    Type: Application
    Filed: September 5, 2019
    Publication date: March 12, 2020
    Inventors: Arun Chowdry, James W. Comb, Chris Counts, J. Samuel Batchelder