公开(公告)号：US20200223653A1

公开(公告)日：2020-07-16

申请号：US16827275

申请日：2020-03-23

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

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：US10384437B2

公开(公告)日：2019-08-20

申请号：US16059275

申请日：2018-08-09

Applicant: Impossible Objects, Inc.

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

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

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：US20190134890A1

公开(公告)日：2019-05-09

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: B29C64/147 ,  B29C64/153 ,  B29C64/393 ,  B29C64/307

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：US20180345648A1

公开(公告)日：2018-12-06

申请号：US16059275

申请日：2018-08-09

Applicant: Impossible Objects, Inc.

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

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

CPC classification number: B33Y10/00 ,  B29B15/105 ,  B29C64/147 ,  B29C64/165 ,  B29C64/386 ,  B29C64/40 ,  B29C70/28 ,  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：US20180264732A1

公开(公告)日：2018-09-20

申请号：US15922158

申请日：2018-03-15

Applicant: Impossible Objects, Inc.

Inventor： Robert Swartz ,  Eugene Gore

IPC: B29C64/357 ,  B29C64/141 ,  B29C64/329 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

CPC classification number: B29C64/357 ,  B29C64/141 ,  B29C64/329 ,  B29K2101/12 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

Abstract: A method and powder system component of an apparatus for use in a printing process is disclosed, and for removing and recycling excess powder. The powder system results in a cutoff point of 3 microns rather than 50 microns of previous systems. The apparatus comprises a powder applicator, a powder remover, a helical cyclone, a powder collector, and two valves that alternately open and close. The two-valve system prevents air backflow. The powder is processed through the two-valve system. The method comprises: valve 1 is closed and powder accumulates; valve2 is closed also; after valve 1 opens, powder goes through (there is no air backflow), then valve 1 closes; then valve 2 opens and allows powder onto a powder applicator; then valve 2 closes; then the cycle starts again.

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.