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Layer Transfusion with Part Heating for Additive Manufacturing

  • US 20130078013A1
  • Filed: 09/21/2012
  • Published: 03/28/2013
  • Est. Priority Date: 09/23/2011
  • Status: Active Grant
First Claim
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1. An additive manufacturing system for printing a thermoplastic part, the additive manufacturing system comprising:

  • an imaging engine configured to develop imaged layers of a thermoplastic-based powder having a fusion temperature;

    a movable build platform;

    a transfer medium having a transfer surface configured to sequentially receive and convey the imaged layers from the imaging engine to the build platform, and having an opposing contact surface;

    a heater configured to heat the imaged layers on the transfer medium to at least the fusion temperature;

    a heater configured to heat a previously transfused layer of a thermoplastic part being printed on the build platform to at least the fusion temperature;

    a heated layer transfusion element configured to transfuse a heated imaged layer conveyed by the transfer medium onto the heated previously fused layer by engaging the contact surface of the transfer medium so that the transfer medium and the heated imaged layer are pressed between the transfuse element and the build platform, and to disengage therefrom without releasing the transfer medium from the transfused layer; and

    a cooling unit configured to actively cool the transfused layer to below the fusion temperature while it remains on the transfer medium, so as to transfix the transfused layer before delaminating it from the transfer medium.

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