Abstract: Waste product from any of a variety of processes (injection molding, selective laser sintering) is processed to form powders that have particle size and distribution optimal for a 3D printing technology known as Composite Based Additive Manufacturing (CBAM). Alternative recycling processes include grinding and sieving, emulsion extruding, and liquid-liquid phase separation.

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 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 method of operating an exoskeleton system that includes obtaining a first set of sensor data from one or more sensors associated with one or more leg actuator units of an exoskeleton system during a user activity, the first set of sensor data indicating a first configuration state of the one or more actuator units; determining, based at least in part on the first set of obtained sensor data, to change configuration of the one or more leg actuator units to a second configuration state to support a user during the user activity; and introducing fluid to one or more fluidic actuators of the one or more leg actuator units to generate the second configuration state by causing the one or more fluidic actuators to apply force at the one or more actuator units.

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 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: Waste product from any of a variety of processes (injection molding, selective laser sintering) is processed to form powders that have particle size and distribution optimal for a 3D printing technology known as Composite Based Additive Manufacturing (CBAM). Alternative recycling processes include grinding and sieving, emulsion extruding, and liquid-liquid phase separation.

Abstract: A coupling system between the frame and the leg assembly of a workstation is described. The coupling system can be configured to selectively attach and detach the leg assembly from the frame. The leg assembly can include an adjustment mechanism. The adjustment mechanism can be configured to adjust the length of the leg. The leg assembly can include a leg coupling feature and the frame can have a frame coupling feature. The leg coupling feature can be configured to engage with the frame coupling feature, for instance to attach the leg to the frame. The workstation can include a latch configured to engage with the leg assembly. Engagement of the latch with the leg assembly can secure a position of the leg with respect to the frame.

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 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: 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 method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

Abstract: A coupling system between the frame and the leg assembly of a workstation is described. The coupling system can be configured to selectively attach and detach the leg assembly from the frame. The leg assembly can include an adjustment mechanism. The adjustment mechanism, can be configured to adjust the length of the leg. The leg assembly can include a leg coupling feature and the frame can have a frame coupling feature. The leg coupling feature can be configured to engage with the frame coupling feature, for instance to attach the leg to the frame. The workstation can include a latch configured to engage with the leg assembly. Engagement of the latch with the leg assembly can secure a position of the leg with respect to the frame.

Abstract: A method/system of mechanical holdowns allows a substrate sheet in a CBAM (composite-based additive manufacturing technology) process to lie flat during printing. The invention includes a process of mechanically clamping sheets to be printed by a print head to a flat platen using a set of barrel cam driven clamping fingers. The finger supports are attached to the platen and the fingers can be raised and lowered with respect to the platen. Each finger can rotate while swinging downward toward a sheet at the edge of the platen. To clamp the sheet, the fingers are rotated to the perpendicular position and swung lower down to pinch the sheet to the platen. The process can include additional steps that release some, but not all, of the fingers to allow the sheet to relax before re-clamping them.

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 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 method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

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.