公开(公告)号：US11674207B2

公开(公告)日：2023-06-13

申请号：US17455118

申请日：2021-11-16

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  John Bayldon ,  Buckley Crist ,  Eugene Gore

IPC分类号： C22C47/02 ,  C22C47/06 ,  C22C47/20 ,  C22C49/14 ,  B33Y30/00 ,  B33Y40/00 ,  B29C64/194 ,  B29C64/205 ,  B29C64/165 ,  B22F10/10 ,  B22F12/00 ,  B22F10/66 ,  B22F7/04 ,  B29C67/00 ,  B33Y10/00 ,  B33Y80/00 ,  B29C64/112 ,  B22F10/73 ,  B22F12/53 ,  B22F10/62 ,  B22F3/02 ,  B22F3/10 ,  B22F7/06 ,  B22F7/08

CPC分类号： C22C47/025 ,  B22F7/04 ,  B22F10/10 ,  B22F10/66 ,  B22F12/00 ,  B29C64/165 ,  B29C64/194 ,  B29C64/205 ,  B29C67/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y80/00 ,  C22C47/062 ,  C22C47/20 ,  C22C49/14 ,  B22F3/02 ,  B22F3/1035 ,  B22F3/1039 ,  B22F7/062 ,  B22F7/08 ,  B22F10/62 ,  B22F10/73 ,  B22F12/53 ,  B22F2007/045 ,  B22F2201/01 ,  B22F2998/10 ,  B22F2999/00 ,  B29C64/112 ,  Y02P10/25 ,  B22F2998/10 ,  B22F10/10 ,  B22F3/02 ,  B22F3/1035 ,  C22C47/20 ,  B22F2998/10 ,  B22F10/10 ,  B22F3/02 ,  B22F3/1039 ,  C22C47/20 ,  B22F2999/00 ,  B22F10/10 ,  B22F7/08 ,  B22F2201/01 ,  B22F2999/00 ,  B22F10/10 ,  B22F7/062 ,  B22F2201/01

摘要： 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.

公开(公告)号：US20210362421A1

公开(公告)日：2021-11-25

申请号：US17324554

申请日：2021-05-19

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Buckley Crist ,  Darren Fill ,  John Bayldon

IPC分类号： B29C64/35 ,  B33Y10/00 ,  B33Y40/20 ,  B29C64/165

摘要： 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.

公开(公告)号：US20210229365A1

公开(公告)日：2021-07-29

申请号：US17156565

申请日：2021-01-23

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Leonard Wanger ,  John Bayldon ,  Jeff Saltzman ,  Charles Pint ,  Eugene Gore ,  Gintaras Vaisnys ,  Giovanni Meier ,  Alon Henson

IPC分类号： B29C64/393 ,  G06T7/00

摘要： 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.

公开(公告)号：US20200223131A1

公开(公告)日：2020-07-16

申请号：US16711313

申请日：2019-12-11

申请人： Impossible Objects Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Buckley Crist

IPC分类号： B29C64/141 ,  B29C65/48 ,  B32B5/02 ,  B32B9/04 ,  B32B5/16 ,  B32B5/30 ,  B32B29/04 ,  B32B29/02 ,  B32B27/06 ,  B32B18/00 ,  B32B5/22 ,  B32B27/08 ,  B32B27/10 ,  B32B27/12 ,  B32B5/12 ,  B32B29/00 ,  B32B5/26 ,  G03G15/22 ,  B29C64/153 ,  B32B9/00 ,  B29C64/20 ,  B32B9/06 ,  B32B27/36 ,  B32B27/14 ,  B32B7/14 ,  B29K105/00 ,  B33Y40/00 ,  B29K101/12 ,  B33Y10/00

摘要： A three-dimensional object comprises substantially planar or flat substrate layers that are folded and stacked in a predetermined order and infiltrated by a hardened material. The object is fabricated by positioning powder on all or part of multiple substrate layers. On each layer, the powder is selectively deposited in a pattern that corresponds to tiles that each have a slice of the object. For each slice, powder is deposited in positions that correspond to positions in the slice where the object exists, and not deposited where the object does not exist. The tiles of each substrate layer are folded and aligned in a predetermined order. Multiple folded substrate layers mat be combined into a single stack. The powder 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.

公开(公告)号：US20180050490A1

公开(公告)日：2018-02-22

申请号：US15803199

申请日：2017-11-03

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Buckley Crist ,  Eugene Gore ,  Joseph M. Jacobson

IPC分类号： G03G15/22 ,  B32B5/02 ,  B32B5/22 ,  B32B5/26 ,  B29K105/00 ,  B29K67/00

CPC分类号： B29C64/153 ,  B29C64/10 ,  B29C64/141 ,  B29C64/147 ,  B29K2023/06 ,  B29K2067/046 ,  B29K2105/251 ,  B29K2105/256 ,  B32B5/02 ,  B32B5/22 ,  B32B5/26 ,  B32B2250/20 ,  B32B2260/021 ,  B32B2260/046 ,  B32B2262/0276 ,  B32B2262/106 ,  B32B2307/50 ,  B32B2307/718 ,  B33Y30/00 ,  G03G15/224 ,  G03G15/225 ,  Y10T428/2481 ,  Y10T428/24826 ,  Y10T428/24843

摘要： A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

公开(公告)号：US20240279423A1

公开(公告)日：2024-08-22

申请号：US18649024

申请日：2024-04-29

申请人： IMPOSSIBLE OBJECTS, INC.

发明人： Robert Swartz ,  Michael Vasquez ,  Buckley Crist ,  Eugene Gore

IPC分类号： C08J11/06 ,  B29B17/02 ,  B29B17/04 ,  B29C64/314 ,  B29K71/00 ,  B29K105/00 ,  B33Y40/10 ,  B33Y70/00

CPC分类号： C08J11/06 ,  B29B17/0404 ,  B29C64/314 ,  B33Y40/10 ,  B33Y70/00 ,  B29B2017/0224 ,  B29B2017/042 ,  B29K2071/00 ,  B29K2105/251 ,  C08J2371/10

摘要： 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.

公开(公告)号：US11679601B2

公开(公告)日：2023-06-20

申请号：US16876035

申请日：2020-05-16

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Drew Marschner

IPC分类号： B41J11/06 ,  B25B5/04

CPC分类号： B41J11/06 ,  B25B5/04

摘要： 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.

公开(公告)号：US20200223653A1

公开(公告)日：2020-07-16

申请号：US16827275

申请日：2020-03-23

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Len Wanger ,  Chris Wagner ,  Brian Conti

IPC分类号： B65H31/26 ,  B29C64/147 ,  B29C64/153 ,  B29C64/393 ,  B29C64/307

摘要： A stacker component of an apparatus for automated manufacturing of three-dimensional composite-based objects for aligning registration of sheets. The stacker includes a sheet catcher; a frame having a base plate with the base plate having tapered registration pins to align a stack of substrate sheets. The registration pins are mounted in the base plate and project vertically to a location just below the sheet catcher. The stacker also has a presser with a press plate and a belt driver system that moves the press plate up and down allowing the press plate to exert downward pressure on the stack and a slide system with two guide rails that enable the base plate to be loaded and unloaded. A conveyor can be disposed so that after a substrate sheet exits a powder or printing system, the sheet is conveyed onto the sheet catcher.

公开(公告)号：US10384437B2

公开(公告)日：2019-08-20

申请号：US16059275

申请日：2018-08-09

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Buckley Crist ,  John Bayldon ,  Chris Wagner ,  Nicholas Tarzian ,  Evangeline Su

IPC分类号： B33Y10/00 ,  B29C64/165 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02 ,  B29B15/10 ,  B29C70/28 ,  B29C64/147 ,  B29C64/386 ,  B29C64/40

摘要： 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.

公开(公告)号：US20190134890A1

公开(公告)日：2019-05-09

申请号：US15922469

申请日：2018-03-15

申请人： Impossible Objects, Inc.

发明人： Robert Swartz ,  Eugene Gore ,  Len Wanger ,  Chris Wagner ,  Brian Conti

IPC分类号： B29C64/147 ,  B29C64/153 ,  B29C64/393 ,  B29C64/307

摘要： A stacker component of an apparatus for automated manufacturing of three-dimensional composite-based objects for aligning registration of sheets. The stacker includes a sheet catcher; a frame having a base plate with the base plate having tapered registration pins to align a stack of substrate sheets. The registration pins are mounted in the base plate and project vertically to a location just below the sheet catcher. The stacker also has a presser with a press plate and a belt driver system that moves the press plate up and down allowing the press plate to exert downward pressure on the stack and a slide system with two guide rails that enable the base plate to be loaded and unloaded. A conveyor can be disposed so that after a substrate sheet exits a powder or printing system, the sheet is conveyed onto the sheet catcher.