公开(公告)号：US10597249B2

公开(公告)日：2020-03-24

申请号：US15922469

申请日：2018-03-15

Applicant: Impossible Objects, Inc.

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

IPC: B65H31/26 ,  B29C64/147 ,  B29C64/153 ,  B29C64/393 ,  B29C64/307 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

Abstract: 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：US20190366701A1

公开(公告)日：2019-12-05

申请号：US16544906

申请日：2019-08-20

Applicant: Impossible Objects Inc.

Inventor： Robert Swartz ,  Eugene Gore ,  Buckley Crist ,  John Balydon ,  Chris Wagner ,  Nicholas Tarzian ,  Evangeline Su

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

Abstract: 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：US20190283277A1

公开(公告)日：2019-09-19

申请号：US16194279

申请日：2018-11-16

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  John Bayldon ,  Buckley Crist ,  Eugene Gore

IPC: B29B15/10 ,  D04H3/12 ,  D04H3/04

Abstract: A tow stabilization method includes applying liquid to a tow having fibers arranged into a non-stabilized spread-out fiber web, applying powder to the web to adhere the powder where liquid was applied, removing powder from where it did not adhere, and fusing the powder remaining on the web to stabilize the fiber arrangement. The liquid may be volatile. The step of fusing may include heating the fiber web. The liquid and/or powder may be selectively applied. Selective application of powder may be used without application of liquid or powder removal. A tow stabilization apparatus includes a liquid applicator, powder applicator, powder remover, and powder fuser. The liquid applicator may include spray nozzles, applicators based on miniature solenoid valves, inkjet printing heads, and roll applicators. The powder remover may include rollers, air blasters, vibrators, sound wave generators, and vacuums. The powder fuser may include heat applicators and chemical reaction initiators.

公开(公告)号：US11969954B2

公开(公告)日：2024-04-30

申请号：US17198780

申请日：2021-03-11

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  John Bayldon ,  Buckley Crist ,  Eugene Gore

IPC: B29C70/30 ,  B22F7/06 ,  B22F10/00 ,  B22F10/20 ,  B22F12/90 ,  B29C64/147 ,  B29C64/232 ,  B29C64/295 ,  B29C64/307 ,  B29C64/393 ,  B29C67/08 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02 ,  B33Y70/00 ,  C22C47/02 ,  C22C47/20 ,  C22C49/14 ,  B22F3/105 ,  B22F3/24 ,  B22F7/04 ,  B22F7/08 ,  B22F10/10 ,  B29C70/52 ,  B32B15/00 ,  B33Y40/20 ,  B33Y70/10

CPC classification number: B29C70/30 ,  B22F7/064 ,  B22F10/00 ,  B22F10/20 ,  B22F12/90 ,  B29C64/147 ,  B29C64/232 ,  B29C64/295 ,  B29C64/307 ,  B29C64/393 ,  B29C67/08 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y70/00 ,  C22C47/025 ,  C22C47/20 ,  C22C49/14 ,  B22F2003/1051 ,  B22F3/24 ,  B22F7/04 ,  B22F2007/042 ,  B22F2007/045 ,  B22F7/08 ,  B22F10/10 ,  B22F2998/10 ,  B22F2999/00 ,  B29C70/528 ,  B32B15/00 ,  B33Y40/20 ,  B33Y50/02 ,  B33Y70/10 ,  C22C2200/02 ,  C22C2200/06 ,  B22F2999/00 ,  B22F10/20 ,  B22F2203/03 ,  B22F2998/10 ,  B22F10/20 ,  B22F2003/247 ,  B22F2999/00 ,  B22F10/20 ,  C22C47/20 ,  B22F2999/00 ,  B22F10/00 ,  B22F2203/03 ,  B22F2998/10 ,  B22F10/00 ,  B22F2003/247 ,  B22F2999/00 ,  B22F10/00 ,  C22C47/20

Abstract: A method and apparatus for resistive heating usable in composite-based additive manufacturing is disclosed. The method includes providing a prepared stack of substrate sheets, placing the stack between electrode assemblies of a compression device, applying a current to thereby heat the stack to a final temperature to liquefy applied powder, compressing the stack to a final height, cooling the stack, and removing the cooled, compressed stack from the compression device. The apparatus comprises at least two plates, a power supply for providing current, a first electrode assembly and a second electrode assembly.

公开(公告)号：US11904549B2

公开(公告)日：2024-02-20

申请号：US17393164

申请日：2021-08-03

Applicant: Impossible Objects, Inc.

Inventor： James Brough ,  Robert Swartz ,  Nick Tarzian ,  Eugene Gore

IPC: B29C64/321 ,  B33Y40/00 ,  B65H3/00 ,  B29C64/245 ,  B29C64/153

CPC classification number: B29C64/321 ,  B29C64/245 ,  B33Y40/00 ,  B65H3/00 ,  B29C64/153

Abstract: A felt gripper head contains two regions of felt material each on plates that slide and form a slight angle with respect to each other during engagement with a fibrous substrate material.

公开(公告)号：US11904536B2

公开(公告)日：2024-02-20

申请号：US17820048

申请日：2022-08-16

Applicant: Impossible Objects Inc.

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

IPC: B29C64/165 ,  B29B15/10 ,  B29C70/28 ,  B29C64/147 ,  B29C70/54 ,  B29C64/386 ,  B29C64/40 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

CPC classification number: B29C64/165 ,  B29B15/105 ,  B29C64/147 ,  B29C64/386 ,  B29C64/40 ,  B29C70/28 ,  B29C70/54 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

Abstract: 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：US11806931B2

公开(公告)日：2023-11-07

申请号：US17156540

申请日：2021-01-23

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Leonard Wanger ,  John Bayldon ,  Drew Marschner ,  Michael Rohrer ,  Gintaras Vaisnys ,  Giovanni Meier

IPC: B29C64/259 ,  B33Y40/00 ,  B29C64/307 ,  B33Y30/00 ,  B33Y50/00 ,  B29C64/386 ,  B22F12/90 ,  B22F12/53 ,  B22F12/70 ,  B22F12/50

CPC classification number: B29C64/259 ,  B22F12/50 ,  B22F12/53 ,  B22F12/70 ,  B22F12/90 ,  B29C64/307 ,  B29C64/386 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/00

Abstract: A bulk ink bag system in a composite-based additive manufacturing process (CBAM) keeps the inkjet heads (cartridges) on printers filled to the proper level of fluid at all times while the process runs. The system includes gravity fed fluid delivery without requiring pumps; is simple to connect and disconnect to system plumbing; has the ability to change ink bags without interrupting the print job or introducing air bubbles into the ink supply; and has the ability to disconnect partially used bags and reconnect them later.

公开(公告)号：US20230339174A1

公开(公告)日：2023-10-26

申请号：US18331668

申请日：2023-06-08

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Eugene Gore ,  Buckley Crist ,  Michael Vasquez ,  John Bayldon

IPC: B29C64/147 ,  B33Y10/00 ,  B33Y80/00 ,  B29C64/153 ,  B33Y70/10 ,  B29C64/245 ,  B29C64/295 ,  B29C64/165 ,  B32B5/02 ,  B32B5/26

CPC classification number: B29C64/147 ,  B33Y10/00 ,  B33Y80/00 ,  B29C64/153 ,  B33Y70/10 ,  B29C64/245 ,  B29C64/295 ,  B29C64/165 ,  B32B5/024 ,  B32B5/26 ,  B32B5/022 ,  B29K2101/10

Abstract: A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material. Each substrate layer is a sheet-like structure that comprises fibers held together by a sodium silicate binder. The substrate layer material may be non-woven or woven. The substrate layer may be a non-woven fiber veil bound by a sodium silicate binder. The fibers may optionally include carbon fibers, ceramic fibers, polymer fibers, glass fibers, metal fibers, or a combination thereof.

公开(公告)号：US11673336B2

公开(公告)日：2023-06-13

申请号：US17156565

申请日：2021-01-23

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Leonard Wanger ,  John Bayldon ,  Jeffrey Saltzman ,  Charles Pint ,  Eugene Gore ,  Gintaras Vaisnys ,  Giovanni Meier ,  Alon Henson

IPC: B29C64/393 ,  G06T7/00 ,  B33Y50/02 ,  B33Y10/00

CPC classification number: B29C64/393 ,  G06T7/001 ,  B33Y10/00 ,  B33Y50/02 ,  G06T2207/30144

Abstract: 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：US11413821B2

公开(公告)日：2022-08-16

申请号：US17156541

申请日：2021-01-23

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Eugene Gore

IPC: B29C64/321 ,  B22F12/50 ,  B33Y30/00

Abstract: A powder refill system for a CBAM process that makes changing a powder container simple and maintains the smallest possible distribution change during the print process. The system automates a constantly low trough powder level during a print and reduces the number of times the powder is recirculated. The system uses a sensor to sense the amount of powder in a tray and a compressed air powder application system to force powder into the system. Powder enters the system from a powder bottle mounted upside-down on a plate with an orifice and mixing chamber and a stainless-steel “aeration stone” This is a fitting with porous walls, where porosity is finer than most of particulate matter of the powder being used. Air can enter through the fitting, broken down into microscopic streams, but powder cannot enter back into the air supplying line. The powder aerosol is then used in the printing/flooding process. A mounting plate allows easy replacement of the powder bottle.