Back to results
US 2025/0065559 A1Published application
Additive manufacturing system and method with smooth surface
OwnerBrian Mulleninventor
Life of this patent
Estimating the term…
Loading patent…
Loading patent…
OwnerBrian Mulleninventor
Estimating the term…
Embodiments herein relate to 3D printing. In an embodiment, a method for printing an article using a selective toner electrophotographic process (“STEP”) includes successively depositing multiple layers of part material and support material, the layers deposited substantially parallel to a first plane: wherein: a) the multiple layers of part material and support material extend in a perpendicular to the first plane; and b) at least some of the layers of part material and support material are separated from each other to form a gap between the layers of part material and layers of support material: 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:
The method of any of the preceding claims, wherein the first plane comprises the X-Y plane.
The method of any of the preceding claims, wherein at least a portion of the flow vector of the part material or support material within the gap includes a component outside of the first plane.
The method of any of the preceding claims, wherein the average width of the gap between the part regions and support regions is from 2 to 8 pixels.
The method of any of the preceding claims, wherein the average width of the gap between the part regions and support regions is from 2 to 7 pixels.
The method of any of the preceding claims, wherein the average width of the gap between the part regions and support regions is from 2 to 6 pixels.
The method of any of the preceding claims, wherein the average width of the gap between the part material and support material is from 5 to 25 pixels.
The method of any of the preceding claims, further comprising reheating, compressing, and recooling the build surface so as to cause the gap to diminish and the part region surface to become progressively smoother.
The method of any of the preceding claims, wherein the surface roughness of vertical part surfaces is less than 8 μm.
The method of any of the preceding claims, wherein the surface roughness of vertical part surfaces is less than 4 μm.
The method of any of the preceding claims, wherein the surface roughness of vertical part surfaces is less than 2 μm.
A method for printing an article using a selective toner electrophotographic process, the method comprising:
The method of any of the preceding claims, wherein at least a portion of the part material and/or support material flows upward in a Z-direction with a component normal to the X-Y plane within the gap.
The method of any of the preceding claims, wherein at least a portion of the part material or support material has a flow vector component outside of the X-Y plane.
The method of any of the preceding claims, wherein the average width of the gap between the part regions and support regions is from 6 to 12 pixels.
The method of any of the preceding claims, wherein the average width of the gap between the part material and support material is from 5 to 25 pixels.
The method of any of the preceding claims, further comprising reheating, compressing, and recooling the build surface so as to cause the gap to diminish and the part region surface to become progressively smoother.
The method of any of the preceding claims, wherein the surface roughness of vertical part surfaces is less than 8 μm.
The method of any of the preceding claims, wherein the surface roughness of vertical part surfaces is less than 4 μm.
The method of any of the preceding claims, wherein the surface roughness of vertical part surfaces is less than 2 μm.
Dependencies are inferred from the claim text.