Off Topic- Personal May interest a few
Meparth singh rajput
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Ashok
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Robert Clark
https://patents.justia.com/patent/20170291261https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20170291261SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a much faster 3D printer using new and novel paradigms that are drawn partly from Scalable Vector Graphics (SVG), partly from Calculus and Making of Geodesic Domes, and partly from Embroidery and other fields such as Welding.
The newly invented 3D printer will print most objects at twenty to twenty five times the speed of existing 3D printers. Those objects whose cross sections consist of straight lines, relatively shallow curves, and large smoothly enclosed cross sectional areas can be printed at nearly thirty times the speed of existing 3D printers. Further, those objects that consist largely of curves of thin cross sectional areas with tight tolerances can be printed at eight to ten times the speed of existing 3D printers.
Printing is done by pre-formed shapes such as rods, boards and arcs, which cover many pixels at one time. Scalable Vector Graphics are used to analyze the cross sectional areas into lines, curves and surface areas. Straight lines are printed directly by rods. Curves are printed by chords that approximate them such that the printed object is within the tolerance specified for it. Surface areas are printed using the long stitch paradigm from embroidery
The wastes of time and motion that are present in the normal 3D printer have been eliminated, and the needed printing time has been vastly reduced. By using pre-formed shapes (such as rods, boards, arcs), the times needed for heating of thermoplastic, extrusion of thermoplastic blobs, capping the extrusion hole and periodic cleaning of the extrusion hole are greatly minimized. By using a new paradigm of tack followed by weld, the time spent inside the print cycle in fusing the thermoplastic material is reduced to a far shorter time of heating for tacking only. By using two or more print-heads simultaneously, instead of only one print-head, the time to print new components is also reduced.
DETAILED DESCRIPTION OF THE ACCOMPANYING EMBODIMENTS
The improved, faster 3D printer of the present invention uses a new paradigm that uses pre-formed shapes such as rods, boards, and arcs to print an image.
Rods:
FIG. 1 shows a perspective drawing of some rods. A rod is a 3D pre-formed shape of material that will be used to print the 3D image. In one embodiment, a rod could be made of the plastic/polymer from which the image is to be printed. In another embodiment, a rod could be made of sintering material coated/cladded with plastic or other suitable materials described later. Rods can have various areas of cross-section that are convenient for the printing job at hand. At the minimum, a rod must be at least one pixel in cross-section. Rods can have different lengths. A rod can be of unit length l, which is a cube 1 but is labeled as a rod for our purposes. A rod can be of two units' length, four units' length, fifteen units' length, and so on. Before the start of the printing process, the printer can choose to load limited types of rods, say five or six rods of different lengths from an inventory of say, without limitation, 25 to 30 different length rods. For understanding, assume that the printer has been loaded with five rods of unit lengths r1 to r5, with r1 being the shortest rod, and r5 being the longest rod. Assume that the lengths of the rods are as follows: r1=1 unit, r2=2 units, r3=4 units, r4=8 units and r5=15 units. The rods of unit length and two units' length are often useful; the other three rods can be of any convenient lengths.
Boards:
There is another 3D pre-formed shape called “boards” that is used to print 3D images. FIG. 2 shows a perspective drawing of some boards. A board is a 3D pre-formed shape used for 3D printing, made up of materials such as plastic/polymer/sintering materials. In one embodiment, a board has a height of unit pixel. In other embodiments, a board's height can be varied according to the convenience of the user in the printing process. Its breadth may be 2, 3, 4, or more unit pixels. Its length can also vary, just as the lengths of rods vary. In the figure, examples for the board is given with breadth 2 and 4 pixel length 7, in second example four by eight 8, and in third example 2 by 16 9. In yet another embodiment, a board may have, for illustration, a height of one pixel, breadth of four pixels, and length of 32 pixels.
Arcs:
Arcs are another 3D pre-formed shape that can be used to print 3D images. FIG. 3 shows a perspective drawing of some arcs. An arc is a 3D pre-formed shape used for 3D printing made up of materials such as plastic/polymer/sintering materials. In one embodiment, an arc has a height of unit pixel 13. Its radius may be 2, 3, 4, or more unit pixels. Its length can vary 14, in the same way as lengths of rods vary.
Robert Clark
Robert Clark
Evolve Additive Solutions is an American additive-manufacturing company that developed STEP, or Selective Thermoplastic Electrophotographic Process. STEP adapts the electrophotographic technology used in laser printers and photocopiers to manufacture three-dimensional parts from engineering thermoplastics such as ABS and nylon.
Instead of tracing each layer with a nozzle, STEP creates an image of the entire layer using extremely fine, electrically charged thermoplastic particles resembling toner. Imaging drums selectively attract the particles in the required pattern. Separate imaging systems can apply build material and removable support material. The completed powder image is transferred to a belt and then deposited onto the growing part, where carefully controlled heat and pressure fuse it to the preceding layers. This process is repeated until the complete build is formed.
STEP is faster than many extrusion-based printing methods because it produces and transfers a complete two-dimensional layer rather than drawing every perimeter and infill line individually. The time required to image a layer is therefore much less dependent on the number of parts or the amount of detail distributed across the build area. Multiple parts can be produced simultaneously with relatively little increase in layer time, making STEP particularly suitable for production quantities rather than just individual prototypes.
The process achieves high dimensional accuracy and fine detail through precise digital imaging, controlled electrostatic placement of very small polymer particles, and accurate registration of each successive layer. Fine particles can reproduce small text, thin ribs, internal mating features and detailed surface textures. Because each complete layer is supported during transfer, STEP can preserve delicate geometry that might be difficult to deposit reliably with an FDM nozzle. Printed support material also stabilizes overhangs, internal passages and complex features during construction.
Heat and pressure fuse each new layer across its surface, producing dense parts with strong bonding between layers. As a result, STEP parts can have nearly isotropic mechanical properties, meaning their strength is much more consistent in the X, Y and Z directions than that of ordinary FDM parts. The combination of whole-layer imaging, fine-particle control, accurate layer registration and pressure-assisted fusion gives STEP its unusual combination of speed, surface quality, mechanical strength and fine feature resolution.
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Adam Ross
On 20 Aug 2026, at 17:17, Robert Clark <clark.rob...@gmail.com> wrote:
Here is another 3D printing technology that fuses entire layers of powder at a time. Claims to be competitive with injection molding. I know of them because I had them print a prototype for a connector concept I designed.
Evolve Additive Solutions is an American additive-manufacturing company that developed STEP, or Selective Thermoplastic Electrophotographic Process. STEP adapts the electrophotographic technology used in laser printers and photocopiers to manufacture three-dimensional parts from engineering thermoplastics such as ABS and nylon.
Instead of tracing each layer with a nozzle, STEP creates an image of the entire layer using extremely fine, electrically charged thermoplastic particles resembling toner. Imaging drums selectively attract the particles in the required pattern. Separate imaging systems can apply build material and removable support material. The completed powder image is transferred to a belt and then deposited onto the growing part, where carefully controlled heat and pressure fuse it to the preceding layers. This process is repeated until the complete build is formed.
STEP is faster than many extrusion-based printing methods because it produces and transfers a complete two-dimensional layer rather than drawing every perimeter and infill line individually. The time required to image a layer is therefore much less dependent on the number of parts or the amount of detail distributed across the build area. Multiple parts can be produced simultaneously with relatively little increase in layer time, making STEP particularly suitable for production quantities rather than just individual prototypes.
The process achieves high dimensional accuracy and fine detail through precise digital imaging, controlled electrostatic placement of very small polymer particles, and accurate registration of each successive layer. Fine particles can reproduce small text, thin ribs, internal mating features and detailed surface textures. Because each complete layer is supported during transfer, STEP can preserve delicate geometry that might be difficult to deposit reliably with an FDM nozzle. Printed support material also stabilizes overhangs, internal passages and complex features during construction.
Heat and pressure fuse each new layer across its surface, producing dense parts with strong bonding between layers. As a result, STEP parts can have nearly isotropic mechanical properties, meaning their strength is much more consistent in the X, Y and Z directions than that of ordinary FDM parts. The combination of whole-layer imaging, fine-particle control, accurate layer registration and pressure-assisted fusion gives STEP its unusual combination of speed, surface quality, mechanical strength and fine feature resolution.
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Ashok Mathur
Ashok
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Robert Clark
Robert Clark
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Adam Ross
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