US 11,654,623 B2
Additive manufacturing system with layers of reinforcing mesh
Barry P. Mandel, Fairport, NY (US); David A. Mantell, Rochester, NY (US); Chu-Heng Liu, Penfield, NY (US); and Mandakini Kanungo, Penfield, NY (US)
Assigned to Xerox Corporation, Norwalk, CT (US)
Filed by Xerox Corporation, Norwalk, CT (US)
Filed on Nov. 11, 2015, as Appl. No. 14/938,227.
Prior Publication US 2017/0129179 A1, May 11, 2017
Int. Cl. B29C 64/236 (2017.01); B33Y 10/00 (2015.01); B29C 64/165 (2017.01); B29C 64/314 (2017.01); B33Y 40/00 (2020.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01); B29K 105/08 (2006.01); B29K 105/12 (2006.01)
CPC B29C 64/165 (2017.08) [B29C 64/236 (2017.08); B29C 64/314 (2017.08); B33Y 40/00 (2014.12); B29K 2105/08 (2013.01); B29K 2105/12 (2013.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12)] 9 Claims
OG exemplary drawing
 
1. A system for forming a three-dimensional structure using an additive manufacturing method comprising:
a substrate;
a plurality of ejectors configured to eject drops of photopolymer material towards the substrate;
a source of ultraviolet (UV) radiation that emits radiation to at least partially cure the photopolymer material ejected from the plurality of ejectors;
an actuator configured to position mesh sheets onto the photopolymer material that has been ejected toward the substrate and is supported by the substrate;
a cutting device;
a source of image data configured to generate image data corresponding to a shape of an uppermost layer of the ejected photopolymer material supported by the substrate; and
a controller operatively connected to the plurality of ejectors, the source of UV radiation, the cutting device, the source of image data, and the actuator, the controller being configured to:
operate at least one ejector in the plurality of ejectors to form at least one layer of the photopolymer material supported by the substrate,
operate the source of UV radiation to cure the at least one layer of photopolymer material at least partially;
operate the cutting device using the image data corresponding to the shape of the uppermost layer of the ejected photopolymer material supported by the substrate that was generated by the source of image data to cut a mesh sheet to produce at least one portion from the mesh sheet having a shape that corresponds to at least a portion of the shape of the uppermost layer of the ejected photopolymer material supported by the substrate;
operate the actuator to position the at least one portion from the mesh sheet on a top surface of the uppermost layer of the ejected photopolymer material supported by the substrate at a location that corresponds to the shape of the at least one portion from the mesh sheet; and
operate the plurality of ejectors to eject additional photopolymer material onto the at least one portion from the mesh sheet to form at least one other layer of photopolymer material on the at least one portion from the mesh sheet and the uppermost layer of the ejected photopolymer material supported by the substrate.