Hybrid electrostatic 3-d printer using laser fusing

Patent metadata

Field	Value
Publication number	US-2017312984-A1
Application number	US-201615140589-A
Country	US
Kind code	A1
Filing date	Apr 28, 2016
Priority date	Apr 28, 2016
Publication date	Nov 2, 2017
Grant date	—

Abstract

A 3-D printer includes a development station positioned to electrostatically transfer layers of material to an intermediate transfer surface, and a transfer station adjacent the intermediate transfer surface. The transfer station is positioned to receive the layers as the intermediate transfer surface moves past the transfer station. Also, a platen is included that moves relative to the intermediate transfer surface. The intermediate transfer surface transfers a layer of the material to the platen each time the platen contacts one of the layers on the intermediate transfer surface at the transfer station to successively form a freestanding stack of the layers on the platen. A fusing station is positioned to apply light to each layer, after each layer is transferred from the transfer station to the platen. The fusing station selectively applies the light to sinter a portion of the material within the layer.

First claim

What is claimed is:

1 . A three-dimensional (3-D) printer comprising:
an intermediate transfer surface; a development station positioned to electrostatically transfer layers of material to said intermediate transfer surface; a transfer station adjacent said intermediate transfer surface, said transfer station is positioned to receive said layers as said intermediate transfer surface moves past said transfer station; a platen moving relative to said intermediate transfer surface, said intermediate transfer surface transfers a layer of said material to said platen each time said platen contacts one of said layers on said intermediate transfer surface at said transfer station to successively form a freestanding stack of said layers on said platen; and a fusing station positioned to apply light to said layer after said layer is transferred from said transfer station to said platen, said fusing station selectively applies said light to sinter a portion of said material within said layer.

2 . The 3-D printer according to claim 1 , said fusing station does not apply said light to a second portion of said material within said layer, and said light heats said portion to sinter said portion together, without heating said second portion, to leave said second portion as a loose, unbound material.

3 . The 3-D printer according to claim 1 , said fusing station does not apply said light to a second portion of said material within said layer, said portion is less than all of said layer, and said portion and said second portion are different portions of said layer.

4 . The 3-D printer according to claim 1 , said fusing station does not apply said light to a second portion of said material within said layer, and
said 3-D printer further comprises a material removal station positioned to remove said second portion to separate said portion from said second portion, and leave a 3-D printed part.

5 . The 3-D printer according to claim 4 , said material removal station comprises an acoustic vibrator or a solvent rinsing device.

6 . The 3-D printer according to claim 1 , further comprising an adhesive station positioned to supply adhesive to said platen, said adhesive promotes transfer of said layers from said intermediate transfer surface to said layers on said platen at said transfer station.

7 . The 3-D printer according to claim 1 , said development station and said transfer station are positioned relative to said intermediate transfer surface such that a point on said intermediate transfer surface, when said intermediate transfer surface moves in a process direction, first passes said development station and then passes said transfer station.

8 . A three-dimensional (3-D) printer comprising:
an intermediate transfer surface; development stations positioned to electrostatically transfer layers of different materials to said intermediate transfer surface; a transfer station adjacent said intermediate transfer surface, said transfer station is positioned to receive said layers as said intermediate transfer surface moves past said transfer station; a platen moving relative to said intermediate transfer surface, said intermediate transfer surface transfers a layer of said different materials to said platen each time said platen contacts one of said layers on said intermediate transfer surface at said transfer station to successively form a freestanding stack of said layers on said platen; and a laser fusing station positioned to apply laser light to each said layer after said layer is transferred from said transfer station to said platen, said laser fusing station selectively applies said laser light to sinter a portion of said different materials within said layer.

9 . The 3-D printer according to claim 8 , said laser fusing station does not apply said laser light to a second portion of said materials within said layer, and said laser light heats said portion to sinter said portion together, without heating said second portion, to leave said second portion as a loose, unbound materials.

10 . The 3-D printer according to claim 8 , said laser fusing station does not apply said laser light to a second portion of said materials within said layer, said portion is less than all of said layer, and said portion and said second portion are different portions of said layer.

11 . The 3-D printer according to claim 8 , said laser fusing station does not apply said laser light to a second portion of said materials within said layer, and
said 3-D printer further comprises a materials removal station positioned to remove said second portion to separate said portion from said second portion, and leave a 3-D printed part.

12 . The 3-D printer according to claim 11 , said materials removal station comprises an acoustic vibrator or a solvent rinsing device.

13 . The 3-D printer according to claim 8 , further comprising an adhesive station positioned to supply adhesive to said platen, said adhesive promotes transfer of said layers from said intermediate transfer surface to said layers on said platen at said transfer station.

14 . The 3-D printer according to claim 8 , said development stations and said transfer station are positioned relative to said intermediate transfer surface such that a point on said intermediate transfer surface, when said intermediate transfer surface moves in a process direction, first passes said development stations and then passes said transfer station.

15 . A three-dimensional (3-D) printer comprising:
an intermediate transfer surface; development stations positioned to electrostatically transfer layers of different materials to said intermediate transfer surface; a transfer station adjacent said intermediate transfer surface, said transfer station is positioned to receive said layers as said intermediate transfer surface moves past said transfer station; a platen moving relative to said intermediate transfer surface, said intermediate transfer surface transfers a layer of said different materials to said platen each time said platen contacts one of said layers on said intermediate transfer surface at said transfer station to successively form a freestanding stack of said layers on said platen; and a laser fusing station positioned to apply laser light to each said layer after said layer is transferred from said transfer station to said platen, said laser fusing station selectively applies said laser light differently to said different materials within said layer to fuse together portions of said different materials within said layer.

16 . The 3-D printer according to claim 15 , said laser fusing station does not apply said laser light to a second portion of said materials within said layer, and said laser light heats said portion to sinter said portion together, without heating said second portion, to leave said second portion as a loose, unbound materials.

17 . The 3-D printer according to claim 15 , said laser fusing station does not apply said laser light to a second portion of said materials within said layer, said portion is less than all of said layer, and said portion and said second portion are different portions of said layer.

18 . The 3-D printer according to claim 15 , said laser fusing station does not apply said laser light to a second portion of said materials within said layer, and
said 3-D printer further comprises a materials removal station positioned to remove said second portion to separate said portion from said second portion, and leave a 3-D printed part.

19 . The 3-D printer ac

Assignees

• Xerox Corp

Inventors

• Ruiz Erwin
• Mcconville Paul J
• Liu Chu-Heng
• Winters James A
• Lefevre Jason M

Classifications

• B22F10/66

  by mechanical means · CPC title

• B22F12/86

  Serial processing with multiple devices grouped · CPC title

• B22F12/55

  Two or more means for feeding material · CPC title

• B22F12/33

  translatory in the deposition plane · CPC title

• B22F10/73

  of powder · CPC title