Additive manufacturing system and method with improved surface finish

A method for printing an article using a selective toner electrophotographic process, the method comprising:

• successively depositing multiple layers of part material and support material, the layers deposited substantially parallel to an X-Y plane;
• wherein:
• a) multiple layers of part material and support material extend in a Z-direction perpendicular to the X-Y plane;
• and
• b) at least some of the layers of part material and support material are separated from each other in the X-Y plane to form a gap between part material and support material within a layer;
• deposit of an edge enhancement layer between at least some of the multiple layers of part material and support material;
• the edge enhancement layer comprising a layer of part material and/or a layer of support material selectively printed adjacent to the gap of a previous layer;
• and
• application of heat and pressure to the part material and support material such that a portion of the part material and support material flows into and at least partially fills the gap between the part material and support material.

A method for printing an article using a selective toner electrophotographic process, the method comprising:

• successively depositing multiple layers of part material and support material, the layers deposited substantially parallel to an X-Y plane;
• wherein:
• a) the multiple layers of part material and support material extend in a Z-direction perpendicular to the X-Y plane;
• and
• b) at least some of the layers of deposited part material and support material are offset from each other in an X or Y direction to form a gap substantially free of part material and support material between the layers of part material and layers of support material, wherein a mass of part material and support material is higher adjacent to the gap than distant from the gap prior to application of heat and pressure;
• and
• application of heat and pressure to the part material and support material such that a portion of the part material and support material flows into and at least partially fills the gap between the part material and support material.