公开(公告)号：US11413790B2

公开(公告)日：2022-08-16

申请号：US17002589

申请日：2020-08-25

Applicant: Impossible Objects Inc.

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

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

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：US20220080676A1

公开(公告)日：2022-03-17

申请号：US17447511

申请日：2021-09-13

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Eugene Gore ,  Buckley Crist

IPC: B29C64/40 ,  B29C64/118 ,  B33Y10/00 ,  B33Y40/20 ,  B29C64/35 ,  B33Y30/00 ,  B29C64/209

Abstract: Apparatus, systems and processes embodying supporting material feedstock for making a support structure for overhangs in a three-dimensional object via a multi-nozzle fused deposition modeling printer, wherein the supporting material is polylactic acid, which is soluble in solution causing base-catalyzed alcoholosis.

公开(公告)号：US20210138783A1

公开(公告)日：2021-05-13

申请号：US17002589

申请日：2020-08-25

Applicant: Impossible Objects Inc.

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

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

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：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：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：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：US11370166B2

公开(公告)日：2022-06-28

申请号：US16711313

申请日：2019-12-11

Applicant: Impossible Objects Inc.

Inventor： Robert Swartz ,  Eugene Gore ,  Buckley Crist

IPC: B29C64/147 ,  B29C65/48 ,  B32B5/22 ,  G03G15/22 ,  B32B5/02 ,  B32B7/14 ,  B32B5/26 ,  B32B5/30 ,  B29C64/153 ,  B32B9/04 ,  B32B27/36 ,  B32B29/00 ,  B32B9/06 ,  B32B27/14 ,  B32B29/02 ,  B32B27/08 ,  B32B27/10 ,  B32B5/16 ,  B32B29/04 ,  B32B27/06 ,  B32B18/00 ,  B32B27/12 ,  B32B5/12 ,  B32B9/00 ,  B29C64/30 ,  B29C64/20 ,  B29C64/141 ,  B29K101/12 ,  B29K105/00 ,  B33Y40/00 ,  B33Y10/00

Abstract: 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：US10377106B2

公开(公告)日：2019-08-13

申请号：US15722653

申请日：2017-10-02

Applicant: Impossible Objects, Inc.

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

IPC: B32B5/26 ,  B29C64/153 ,  B29C64/141 ,  G03G15/22 ,  B29C70/22 ,  B33Y70/00 ,  B32B5/02 ,  B32B1/00 ,  B32B7/14 ,  B29L9/00

Abstract: A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. 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. Flattening a substrate layer involves reducing planar inconsistencies or imperfections, and comprises applying heat to each substrate layer, cooling the substrate layers, and optionally applying tension and/or pressure to the heated and cooled substrate layers.