Abstract: A maintenance method for a three-dimensional printer includes operating a platform to move along a first track past a first position where the first track is coupled to a second track, and along the second track in a process direction to a position opposite an ejector head positioned opposite the second track. The method operates the platform to (1) perform an operation on the ejector head positioned opposite the second track, (2) move the platform along the second track to a second position that is past the ejector head in the process direction, and (3) operates a switch to selectively couple the second track to the first track at the second position. The method also operates the platform to move past the second position to enable the platform to return to the first track.

Abstract: A printing system includes a housing, a track supported by the housing, and a cart which rides along the track. The printing system also includes print heads which eject material onto the cart. To prevent material from inadvertently accumulating on the track and the housing, the cart also includes a wiper configured to wipe the material from at least a portion of the housing. The printing system also includes at least one collection tray configured to direct and/or collect the material wiped from the housing. The printing system further includes a coating applied to outer surfaces of at least some of the elements of the housing, the track, and the cart to further prevent the material from inadvertently accumulating on the track and the housing. The coating can be a siloxyfluorocarbon coating.

Abstract: Devices and methods for a setscrew device. An elongated cylindrical rod has a first threaded portion with a first diameter and a continuous spiraling thread, an unthreaded shank portion with a second diameter, and a second threaded portion having the second diameter and a continuous spiraling thread. The second diameter is smaller than the first diameter. The unthreaded shank portion is located between the first threaded portion and the second threaded portion forming a step. A bias element is disposed on the step and surrounds the second threaded portion. A compression element is threaded onto the second threaded portion and operatively connected to the bias element.

Abstract: A maintenance method for a three-dimensional printer includes operating a platform to move along a second track past a first position where the second track is coupled to a first track, and along the first track in a process direction to a position opposite an ejector head positioned opposite the first track. The method operates the platform to (1) perform an operation on the ejector head positioned opposite the first track, (2) move the platform along the first track to a second position that is past the ejector head in the process direction, and (3) operates a switch to selectively couple the first track to the second track at the second position. The method also operates the platform to move past the second position to enable the platform to return to the second track.

Abstract: A maintenance system for a three-dimensional printer includes a platform configured to move along a first track. An ejector head is positioned opposite a first portion of the first track. A second track is coupled to the first track at a first position prior to the ejector head, and is selectively coupled to the first track after the ejector head at a second position. A controller is configured to operate the platform to move along the second track to the first position along the first track and past the ejector head, operate the platform to perform an operation on the ejector head, and operate the platform to move along the first track to the second position to enable the platform to return to the second track.

Abstract: An optical sensor enables a level of reflective fluid to be detected. The optical sensor includes a prism mounted at one end of a housing. The prism has an exterior surface that is parallel to the end of the housing and a width that corresponds to a width of the end of the housing. A photoemitter and a photodetector are mounted at another end of the housing to enable light emitted by the photoemitter to be reflected by the prism when the prism contacts reflective fluid and to enable light emitted by the photoemitter to pass out of the sensor when the prism is in contact with air.

Abstract: A maintenance system for a three-dimensional object printer includes a platform having a plurality of wheels that enable the platform to move along a first track, and having a maintenance mechanism connected to the platform so as to be movable normal to the first track. The maintenance mechanism includes a lifting member that extends laterally from the platform, and a maintenance tool configured to move with the lifting member. A lifting platform is positioned laterally offset from a location of the first track where an ejector head is positioned opposite the first track, and is configured to engage with the lifting member to lift the maintenance tool and enable the maintenance tool to perform a maintenance operation on the ejector head.

Abstract: A printing system includes a housing, a track supported by the housing, and a cart which rides along the track. The printing system also includes print heads which eject material onto the cart. To prevent material from inadvertently accumulating on the track and the housing, the cart also includes a wiper configured to wipe the material from at least a portion of the housing. The printing system also includes at least one collection tray configured to direct and/or collect the material wiped from the housing. The printing system further includes a coating applied to outer surfaces of at least some of the elements of the housing, the track, and the cart to further prevent the material from inadvertently accumulating on the track and the housing. The coating can be a siloxyfluorocarbon coating.

Abstract: A maintenance system for a three-dimensional object printer includes a platform having a plurality of wheels that enable the platform to move along a first track, and having a maintenance mechanism connected to the platform so as to be movable normal to the first track. The maintenance mechanism includes a lifting member that extends laterally from the platform, and a maintenance tool configured to move with the lifting member. A lifting platform is positioned laterally offset from a location of the first track where an ejector head is positioned opposite the first track, and is configured to engage with the lifting member to lift the maintenance tool and enable the maintenance tool to perform a maintenance operation on the ejector head.

Abstract: A printing system for forming three-dimensional objects includes two laterally spaced rails, each of the rails have an internal cavity extending through the rail along a longitudinal axis. The printing system further includes two heating devices, one heating device is connected to the internal cavity of one of the two laterally spaced rails and the other heating device is connected to the internal cavity of the other of the two laterally spaced rails to enable each heating device to heat a surface of the rail in which the heating device is positioned. The printing system further includes a platform configured to move along the laterally spaced rails. The printing system also includes at least one of a pair of scrapers, wiper pads, and wiper blades mounted to the cart.

Abstract: A maintenance system for a three-dimensional printer includes a platform configured to move along a first track. An ejector head is positioned opposite a first portion of the first track. A second track is coupled to the first track at a first position prior to the ejector head, and is selectively coupled to the first track after the ejector head at a second position. A controller is configured to operate the platform to move along the second track to the first position along the first track and past the ejector head, operate the platform to perform an operation on the ejector head, and operate the platform to move along the first track to the second position to enable the platform to return to the second track.

Abstract: A printing system for forming three-dimensional objects includes two laterally spaced rails, each of the rails have an internal cavity extending through the rail along a longitudinal axis. The printing system further includes two heating devices, one heating device is connected to the internal cavity of one of the two laterally spaced rails and the other heating device is connected to the internal cavity of the other of the two laterally spaced rails to enable each heating device to heat a surface of the rail in which the heating device is positioned. The printing system further includes a platform configured to move along the laterally spaced rails. The printing system also includes at least one of a pair of scrapers, wiper pads, and wiper blades mounted to the cart.

Abstract: An optical sensor enables a level of reflective fluid to be detected. The optical sensor includes a prism mounted at one end of a housing. The prism has an exterior surface that is parallel to the end of the housing and a width that corresponds to a width of the end of the housing. A photoemitter and a photodetector are mounted at another end of the housing to enable light emitted by the photoemitter to be reflected by the prism when the prism contacts reflective fluid and to enable light emitted by the photoemitter to pass out of the sensor when the prism is in contact with air.

Abstract: An apparatus detects inoperative inkjets during printing of three-dimensional objects. The apparatus includes an optical sensor with a predetermined focal plane. The optical sensor is moved to a position that enables the sensor to generate image data of material drops ejected by a group of inkjets in a single row of a printhead. These image data are analyzed to detect inoperative inkjets to enable printhead maintenance at appropriate times to maintain the operational status of the inkjets in the printhead. The optical sensor is moved along a length and width of the printhead to enable the sensor to generate image data of all the inkjets that eject material from the printhead.

Abstract: An apparatus detects inoperative inkjets during printing of three-dimensional objects. The apparatus includes an optical sensor that generates measurements of a height, a diameter, and a position for test dots formed on a substrate with material ejected from a printhead. These measurements are analyzed to detect inoperative inkjets to enable printhead maintenance at appropriate times to maintain the operational status of the inkjets in the printhead.

Abstract: A maintenance system for maintaining a scalable printhead array comprises: a pair of tracks disposed in parallel and on opposite sides of a printhead array; a shaft extending between the tracks and configured to engage with each track to move along the tracks; a plurality of maintenance modules mounted in series along the shaft between the tracks and configured to move along the tracks with the shaft to perform maintenance operations on a plurality of printheads of the printhead array, the tracks being configured to guide the shaft and the plurality of maintenance modules along a path from a resting position to an operating position the printhead array and from which at least one of the plurality of maintenance modules performs a maintenance operation on at least one printhead of the printhead array; and an actuator configured to move the shaft along the tracks.

Abstract: An apparatus detects inoperative inkjets during printing of three-dimensional objects. The apparatus includes a roll of substrate that extends to a take up roller. A printhead prints a test pattern on a portion of the substrate pulled from the roll and the portion with the test pattern is moved opposite a digital camera. The digital camera generates data of the test pattern on the substrate and these data are analyzed to identify inoperative inkjets in the printhead.

Abstract: A latch apparatus for retaining a flexible circuit cable within a receptacle mounted on a circuit board comprises a latch body having a second planar side comprising opposing alignment pins positioned at a first edge and a second edge of the body. A second end of the body comprises alignment protrusions extending from the second end in a first direction. The second end also comprises clamping protrusions extending from the second end in the first direction. The clamping protrusions are a distance from the alignment protrusions equal to a thickness of the circuit board. A latch member extends from the second end. The latch member comprises a linear clip surface extending from the latch in a direction perpendicularly away from the second planar side, and the linear clip surface runs in a second direction and has a length less than a width of the receptacle.

Abstract: A latch apparatus for retaining a flexible circuit cable within a receptacle mounted on a circuit board comprises a latch body having a second planar side comprising opposing alignment pins positioned at a first edge and a second edge of the body. A second end of the body comprises alignment protrusions extending from the second end in a first direction. The second end also comprises clamping protrusions extending from the second end in the first direction. The clamping protrusions are a distance from the alignment protrusions equal to a thickness of the circuit board. A latch member extends from the second end. The latch member comprises a linear clip surface extending from the latch in a direction perpendicularly away from the second planar side, and the linear clip surface runs in a second direction and has a length less than a width of the receptacle.

Abstract: An apparatus detects inoperative inkjets during printing of three-dimensional objects. The apparatus includes a roll of substrate that extends to a take up roller. A printhead prints a test pattern on a portion of the substrate pulled from the roll and the portion with the test pattern is moved opposite a digital camera. The digital camera generates data of the test pattern on the substrate and these data are analyzed to identify inoperative inkjets in the printhead.