Electrophotography-based additive manufacturing with powder density detection and utilization
First Claim
1. An additive manufacturing system for printing a three-dimensional part, the additive manufacturing system comprising:
- one or more electrophotography engines configured to develop one or more layers of the three-dimensional part;
a rotatable transfer belt configured to receive the one or more developed layers from the one or more electrophotography engines;
a detector configured to measure at least one parameter related to a powder density corresponding to one developed layer of the one or more developed layers on the rotatable transfer belt, and to transmit signals relating to the measured at least one parameter for at least one of the developed layers;
a printing assembly configured to receive the developed layer from the rotatable transfer belt and to print the three-dimensional part from the developed layers; and
a controller assembly configured to receive the transmitted signals from the detector, compare the received signals to a set point, and adjust one or more process parameters while developing one or more subsequent layers based on a difference between the received signals and the set point.
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Abstract
An additive manufacturing system for printing a three-dimensional part, which includes one or more electrophotography engines configured to develop layers of the three-dimensional part, a rotatable transfer belt configured to receive the developed layers from the electrophotography engine(s), a detector configured to measure powder densities of the developed layers on the rotatable transfer belt, and to transmit signals relating to the measured powder densities to a controller assembly, and a printing assembly configured to receive the developed layer from the rotatable transfer belt and to print the three-dimensional part from the developed layers.
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Citations
19 Claims
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1. An additive manufacturing system for printing a three-dimensional part, the additive manufacturing system comprising:
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one or more electrophotography engines configured to develop one or more layers of the three-dimensional part; a rotatable transfer belt configured to receive the one or more developed layers from the one or more electrophotography engines; a detector configured to measure at least one parameter related to a powder density corresponding to one developed layer of the one or more developed layers on the rotatable transfer belt, and to transmit signals relating to the measured at least one parameter for at least one of the developed layers; a printing assembly configured to receive the developed layer from the rotatable transfer belt and to print the three-dimensional part from the developed layers; and a controller assembly configured to receive the transmitted signals from the detector, compare the received signals to a set point, and adjust one or more process parameters while developing one or more subsequent layers based on a difference between the received signals and the set point. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:
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producing a developed layer of a part material with an electrophotography engine of the additive manufacturing system; transferring the developed layer from the electrophotography engine to a transfer belt of the additive manufacturing system; rotating the transfer belt with the developed layer; measuring a parameter related to a powder density of the developed layer on the rotating transfer belt with a detector; transmitting signals related to the measured parameter related to the powder density of the developed layer to a controller assembly; comparing the signals to a set point with the controller assembly; heating the developed layer on the rotating transfer belt after measuring the powder density; pressing the heated developed layer into contact with a top surface of the three-dimensional part; and producing one or more subsequent developed layers by adjusting one or more process parameters based on a difference between the received signals and the set point. - View Dependent Claims (9, 10, 11, 12)
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13. A method for measuring a capacitance of a developed layer, and utilizing the measured capacitance for adjusting one or more process parameters, in an additive manufacturing system, the method comprising:
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rotating a transfer belt of the additive manufacturing system; measuring one or more capacitance values of the rotating transfer belt in a clean state with a detector; determining a baseline capacitance value from the one or more measured capacitance values for the rotating transfer belt; producing the developed layer from a powder-based material with an electrophotography engine of the additive manufacturing system; transferring the developed layer from the electrophotography engine to the rotating transfer belt; measuring one or more capacitance values of the developed layer on the rotating transfer belt with the detector; determining a sample capacitance value from the one or more measured capacitance values for the developed layer on the rotating transfer belt; determining a difference between the sample capacitance value and the baseline capacitance value; and producing one or more subsequent developed layers by adjusting one or more process parameters based on the determined difference. - View Dependent Claims (14, 15, 16, 17, 18, 19)
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Specification