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：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：US12186852B2

公开(公告)日：2025-01-07

申请号：US17393134

申请日：2021-08-03

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Michael Sutin

IPC: B23Q3/18 ,  B29C64/245 ,  B29C64/307 ,  B29C64/314 ,  B33Y30/00 ,  B33Y40/00

Abstract: A stacker for a 3D printer apparatus contains a positioning conveyor and a support plate hinged to drop on a signal, whereupon a push plate will push a printed and powdered sheet downward and onto registration pins, to form a stacked register of such sheets.

公开(公告)号：US20240424729A1

公开(公告)日：2024-12-26

申请号：US18823007

申请日：2024-09-03

Applicant: IMPOSSIBLE OBJECTS, INC.

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

IPC: B29C64/153 ,  B29C64/10 ,  B29C64/141 ,  B29C64/147 ,  B29K67/00 ,  B29K105/00 ,  B32B5/02 ,  B32B5/22 ,  B32B5/26 ,  B33Y30/00 ,  G03G15/22

Abstract: A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: 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.

公开(公告)号：US20240279423A1

公开(公告)日：2024-08-22

申请号：US18649024

申请日：2024-04-29

Applicant: IMPOSSIBLE OBJECTS, INC.

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

IPC: C08J11/06 ,  B29B17/02 ,  B29B17/04 ,  B29C64/314 ,  B29K71/00 ,  B29K105/00 ,  B33Y40/10 ,  B33Y70/00

CPC classification number: C08J11/06 ,  B29B17/0404 ,  B29C64/314 ,  B33Y40/10 ,  B33Y70/00 ,  B29B2017/0224 ,  B29B2017/042 ,  B29K2071/00 ,  B29K2105/251 ,  C08J2371/10

Abstract: Waste product from any of a variety of processes (injection molding, selective laser sintering) is processed to form powders that have particle size and distribution optimal for a 3D printing technology known as Composite Based Additive Manufacturing (CBAM). Alternative recycling processes include grinding and sieving, emulsion extruding, and liquid-liquid phase separation.

公开(公告)号：US11679601B2

公开(公告)日：2023-06-20

申请号：US16876035

申请日：2020-05-16

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Eugene Gore ,  Drew Marschner

IPC: B41J11/06 ,  B25B5/04

CPC classification number: B41J11/06 ,  B25B5/04

Abstract: A method/system of mechanical holdowns allows a substrate sheet in a CBAM (composite-based additive manufacturing technology) process to lie flat during printing. The invention includes a process of mechanically clamping sheets to be printed by a print head to a flat platen using a set of barrel cam driven clamping fingers. The finger supports are attached to the platen and the fingers can be raised and lowered with respect to the platen. Each finger can rotate while swinging downward toward a sheet at the edge of the platen. To clamp the sheet, the fingers are rotated to the perpendicular position and swung lower down to pinch the sheet to the platen. The process can include additional steps that release some, but not all, of the fingers to allow the sheet to relax before re-clamping them.