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.
B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
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.
B05D 1/26 - Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
B05D 1/40 - Distributing applied liquids or other fluent materials by members moving relatively to surface
3.
THREE-DIMENSIONAL PRINTED COMPOSITES USING ENGINEERED POWDERS
A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material comprising engineered powder that 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. The powder may be emulsion aggregation powder, chemically -produced toner powder, or a combination. It may be a thermoplastic or thermosettable polymer and may include nylon, elastomers, polyolefins, polyethylene, polyether ether ketone, polyimide, polyetherimide, polyphenylene sulfide, polystyrene, polypropylene, polymethyl methacrylate, and polyaryletherketone, or a combination. The powder particles may have a pre-specified controlled shape and/or anon-homogenous composition. Surface treatments and/or additives may be used to control powder flow and charge distribution. Each substrate layer may be a sheet-like structure comprising fibers held together by binder. The binder may include sodium silicate.
A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.
B22F 7/04 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite layers with one or more layers not made from powder, e.g. made from solid metal
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor
C22C 47/02 - Pretreatment of the fibres or filaments
C22C 47/06 - Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
C22C 47/20 - Making alloys containing metallic or non-metallic fibres or filaments by subjecting to pressure and heat an assembly comprising at least one metal layer or sheet and one layer of fibres or filaments
C22C 49/14 - Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
B29C 67/00 - Shaping techniques not covered by groups , or
B33Y 80/00 - Products made by additive manufacturing
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
B22F 7/08 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
5.
METHOD AND APPARATUS FOR AUTOMATED COMPOSITE-BASED ADDITIVE MANUFACTURING
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.
An additive manufacturing method and apparatus is described for the printing of three-dimensional (3D) objects. The approach is based on a composite-based additive manufacturing process, except it uses commercial printing methods to achieve even higher speed and throughput. By using the invention, a prototyping and/or production process may be completed in hours rather than months, and the risks and problems of molds is eliminated. There is substantial improvement in the number and type of geometries that can be produced compared to injection molding, and the range of materials is enlarged as are the material properties. The method involves printing a substrate having at least one sheet using a printing technology, and stacking or folding the at least one sheet to form multiple layers consistent with that formed by a 3D model. The printing step is done using a printing technology such as flexography, lithography, offset, gravure, waterless printing, and silkscreen.
A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor
B22F 7/04 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite layers with one or more layers not made from powder, e.g. made from solid metal
B29C 67/00 - Shaping techniques not covered by groups , or
16 - Paper, cardboard and goods made from these materials
35 - Advertising and business services
40 - Treatment of materials; recycling, air and water treatment,
42 - Scientific, technological and industrial services, research and design
Goods & Services
Paints, varnishes, lacquers; preservatives against rust and against deterioration of wood; colorants; mordants; raw natural resins; metals in foil and powder form for use in painting, decorating, printing and art; aluminium paints; aluminium powder for painting; anti-rust preparations; asbestos paints; bactericidal paints; binding preparations for paints; ceramic paints; coatings [paints]; colorants; copying inks; dyes; edible inks; enamels for painting; enamels [varnishes]; fireproof paints; engraving ink; glazes [paints, lacquers]; ink for leather; metal foil for use in painting, decorating, printing and art; metals in powder form for use in painting, decorating, printing and art; natural resins, raw; pigments; primers; printing ink; thickeners for paints; thinners for paints; toner cartridges, filled, for printers and photocopiers; toners [ink] for photocopiers; edible ink cartridges, filled, for printers; ink (printing); printing pigments; printing paste; printing toner; printing compositions [ink]; drying additives for printing inks; ultra violet light-cured printing inks; colorants for the production of printing inks; paints for use in the printing industry; varnishes for use in the printing industry; printing inks for use in the graphic arts industry; parts and fittings for all the aforesaid goods. Machine tools; motors and engines [except for land vehicles]; machine coupling and transmission components [except for land vehicles]; agricultural implements other than hand-operated; incubators for eggs; automatic vending machines; adhesive tape dispensers [machines]; air brushes for applying colour; air condensers; ball-bearings; bearing brackets for machines; belts for machines; packaging tools [machines]; blades [parts of machines]; blowing machines; brushes [parts of machines]; compressed air machines; compressed air pumps; packing machines for wrapping; control cables for machines, engines or motors; control mechanisms for machines, engines or motors; current generators; dyeing machines; fans for motors and engines; generators of electricity; glue guns, electric; machines for making packing material; 3D printers; guides for machines; pack assembling machines; hand-held tools, other than hand-operated; labellers [machines]; inking apparatus for printing blocks; inking apparatus for printing machines; painting machines; pulleys; pumps [machines]; machines for manufacturing containers; machines for manufacturing packaging materials; machines for manufacturing semi-conductors; sealing machines for industrial purposes; springs [parts of machines]; stamping machines; tables for machines; tools [parts of machines]; typographic machines; type-setting machines [printing]; typographic presses; valves [parts of machines]; waste compacting machines; woodworking machines; wrapping machines; inking apparatus for printing machines; electrical apparatus for sealing plastics [packaging]; printing cylinders; printing machines; printing rollers for machines; vacuum packing machines; packaging apparatus [machines]; stretch-wrapping machines for applying plastics material to palletised loads; parts and fittings for all the aforesaid goods. Adhesives for stationery or household purposes; typewriters and office requisites [except furniture]; instructional and teaching material [except apparatus]; plastic materials for packaging; printers' type; printing blocks; hand labelling appliances; ink; inking pads; inking ribbons; inking ribbons for computer printers; inking sheets for document reproducing machines; inking sheets for duplicators; plastic bubble packs for wrapping or packaging; plastic cling film, extensible, for palletization; plastic film for wrapping; printing blocks; printing sets, portable [office requisites]; printing type; stuffing of paper or cardboard; ink sheets for use in reproducing images in the printing industry; packaging materials; adhesive packaging tapes; airtight packaging of paper; airtight packaging of cardboard; blister packs for packaging; packaging boxes of card; packaging wrappers of plastic; plastic and paper bags for packaging; printed packaging materials of paper; paperboard boxes for industrial packaging; rolls of plastic film for packaging; packaging materials made of recycled paper; parts and fittings for all the aforesaid goods. Distribution of samples; document reproduction; online retail services in relation to printers; provision of commercial information in the field of printers; retail services in relation to paints, varnishes, lacquers, preservatives against rust and against deterioration of wood, colorants, mordants, raw natural resins, metals in foil and powder form for use in painting, decorating, printing and art, aluminium paints, aluminium powder for painting, anti-rust preparations, asbestos paints, bactericidal paints, binding preparations for paints, ceramic paints, coatings [paints], colorants, copying inks, dyes, edible inks; retail services in relation to enamels for painting, enamels [varnishes], fireproof paints, engraving ink, glazes [paints, lacquers], ink for leather, metal foil for use in painting, decorating, printing and art, metals in powder form for use in painting, decorating, printing and art, natural resins, raw, pigments, primers, printing ink, thickeners for paints, thinners for paints, toner cartridges, filled, for printers and photocopiers, toners [ink] for photocopiers; retail services in relation to edible ink cartridges, filled, for printers, ink (printing), printing pigments, printing paste, printing toner, printing compositions [ink], drying additives for printing inks, ultra violet light-cured printing inks, colorants for the production of printing inks, paints for use in the printing industry, varnishes for use in the printing industry, printing inks for use in the graphic arts industry, machine tools, motors and engines [except for land vehicles]; retail services in relation to machine coupling and transmission components [except for land vehicles], agricultural implements other than hand-operated, incubators for eggs, automatic vending machines, adhesive tape dispensers [machines], air brushes for applying colour, air condensers, ball-bearings, bearing brackets for machines, belts for machines, packaging tools [machines], blades [parts of machines], blowing machines, brushes [parts of machines], compressed air machines, compressed air pumps; retail services in relation to packing machines for wrapping, control cables for machines, engines or motors, control mechanisms for machines, engines or motors, current generators, dyeing machines, fans for motors and engines, generators of electricity, glue guns, electric, machines for making packing material, 3D printers, guides for machines, pack assembling machines, hand-held tools, other than hand-operated, labellers [machines], inking apparatus for printing blocks; retail services in relation to inking apparatus for printing machines, painting machines, pulleys, pumps [machines], machines for manufacturing containers, machines for manufacturing packaging materials, machines for manufacturing semi-conductors, sealing machines for industrial purposes, springs [parts of machines], stamping machines, tables for machines, tools [parts of machines], typographic machines, type-setting machines [printing], typographic presses, valves [parts of machines]; retail services in relation to waste compacting machines, woodworking machines, wrapping machines, inking apparatus for printing machines, electrical apparatus for sealing plastics [packaging], printing cylinders, printing machines, printing rollers for machines, print heads for ink-jet printers, vacuum packing machines, packaging apparatus [machines], stretch-wrapping machines for applying plastics material to palletised loads, paper and cardboard, printed matter, bookbinding material; retail services in relation to hand labelling appliances, ink, inking pads, inking ribbons, inking ribbons for computer printers, inking sheets for document reproducing machines, inking sheets for duplicators, for packaging, boxes of cardboard or paper, composing frames [printing], packaging material made of starches, packing [cushioning, stuffing] materials of paper or cardboard, plastic bubble packs for wrapping or packaging, plastic cling film, extensible, for palletization, plastic film for wrapping, printing blocks, printing sets, portable [office requisites]; retail services in relation to printing type, stuffing of paper or cardboard, ink sheets for use in reproducing images in the printing industry, packaging materials, adhesive packaging tapes, airtight packaging of paper, airtight packaging of cardboard, blister packs for packaging, packaging boxes of card, packaging wrappers of plastic, plastic and paper bags for packaging; retail services in relation to printed packaging materials of paper, paperboard boxes for industrial packaging, rolls of plastic film for packaging, packaging materials made of recycled paper and printed matter; wholesale services in relation to printers and printed matter; information, advisory and consultancy services relating to the aforesaid. Abrasion; application of finishes to textiles; application of relief patterns to board surfaces; application of relief patterns to card surfaces; application of relief patterns to paper surfaces; applying finish to stainless steel sheets and coils; applying finishes to textiles; assembly of products for others; assembly of toys for others; blast treatment; blueprinting; brushing of textiles; casting; colour separation services; custom assembling of materials; custom manufacturing; cutting of sheet glass; cutting of metal; digital printing; document destruction; electrochemical treatment; embossing services, namely, embossing words, designs or images on plastic, polyester, para-aramid synthetic fiber or silk; enamelling; engraving; etching; galvanization; galvanisation; gilding; grinding; hardening of metals; heat treatment of metals; intaglio printing; laminating; laser engraving; letterpress printing; lithographic printing; material treatment information metal brazing; metal casting; metal coating; metal cutting, metal finishing, metal forging, metal hardening; metal moulding; metal treatment; metal pressing; moulding of synthetic products; moulding textiles; paper finishing; paper treating; parts moulding; pattern printing; pattern cutting; plating (metal -); provision of information relating to printing services; recovery of precious metals; recycling of metals; refining of metals; refining services; rental of machines and apparatus for treating textiles; rental of metal-treating machines and tools; surface plating; tanning; textile finishing; textile treating; three-dimensional printing [3DP]; treatment of metals; typesetting; vulcanization [material treatment]; manufacturing services for others in the field of aerospace components, athletic sporting goods, aviation components, automobile parts, industrial components, marine vessel parts, prosthetics, robotic components and mechanisms, and tool bits; additive manufacturing of aerospace components, athletic sporting goods, aviation components, automobile parts, industrial components, marine vessel parts, prosthetics, robotic components and mechanisms, and tool bits; additive manufacturing; custom manufacture of prosthetics; custom manufacture of goods; custom manufacture of thermoplastic components; custom manufacture of tools for others; custom manufacture of moulds for use in industry; contract manufacturing in the field of aerospace components, athletic sporting goods, aviation components, automobile parts, industrial components, marine vessel parts, prosthetics, robotic components and mechanisms, and tool bits; manufacture of general product lines in the field of aerospace components, athletic sporting goods, aviation components, automobile parts, industrial components, marine vessel parts, prosthetics, robotic components and mechanisms, and tool bits to the order and specification of others; treatment of materials, namely the addition of carbon fibre, para-aramid synthetic fiber and fiberglass to ceramics, concrete, glass, metals, polymers, plastics, semiconductors and wood; consulting services related to printing and tree-dimensional printing. Analysis and evaluation of product design in relation with three-dimensional printing [3DP]; computer aided design services in connection with three-dimensional printing [3DP]; computer aided design for manufacturing operations in connection with three-dimensional printing [3DP]; design consultancy in connection with three-dimensional printing [3DP]; design of packaging; design of software for use with printing machines; design of packaging and wrapping materials; design and development of computer hardware for the manufacturing industries; industrial design services in connection with three-dimensional printing [3DP]; product development consultation in connection with three-dimensional printing [3DP]; design of printed matter in connection with three-dimensional printing [3DP]; design of printed material in connection with three-dimensional printing [3DP]; design of software for use with printing machines; advisory services relating to computer software used for printing; design, development related to printing and three-dimensional printing; testing the functionality of machines in the nature of manufacturing machines and printing machines; information, advisory and consultancy services relating to the aforesaid.
A distributed heterogeneous or homogeneous file storage system divides logical responsibility for data from actual control of the data by using separate file and storage managers. Each file manager provides access to stored files and stores metadata associated with each of the files for which it is responsible. A file manager control component allocates responsibilities among file managers, assigns management responsibilities for individual files, and maintains a record of which files are assigned to each manager. Each storage manager is responsible for managing storage of files on data storage devices and maintains a record of the location of each stored file. A storage manager control component allocates responsibilities among storage managers, assigns responsibilities for individual files, and maintains a record of which files and storage devices are assigned to each manager. A client provides user access, initiates actions within the system, and implements a redundant data recovery and reconstruction scheme.
G06F 11/20 - Error detection or correction of the data by redundancy in hardware using active fault-masking, e.g. by switching out faulty elements or by switching in spare elements
11.
METHODS AND APPARATUS FOR THREE-DIMENSIONAL PRINTED COMPOSITES
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.
In an illustrative implementation of this invention, a 3D object 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. 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.
