An electrostatic oiling system for use with single blanks in batch systems having an open spray chamber without the need for a negative vacuum chamber. Further, the provided electrostatic oiling system may utilize induction beams and a charge wall that allows for utilization of a smaller vacuum system. Further, the provided electrostatic oiling system may provide variable blank coverage without the need for metered pumps.

To improve actual coating efficiency, the present invention has a coating robot provided with a coating unit configured by a plurality of rotary atomizing type electrostatic coating machines horizontally arranged, and a coating control apparatus that controls the coating unit and the coating robot. A diameter of each of bells is 50 mm or less. The coating material discharge amount of each rotary atomizing type electrostatic coating machine is 400 cc/min or less. A coating distance between each bell and a surface to be coated of a workpiece is controlled between 50 mm to 150 mm. The coating material discharge amounts of the plurality of electrostatic coating machines are controlled for the respective coating machines. The control of the coating material discharge amounts includes a pause of coating material discharge.

To improve actual coating efficiency, the present invention has a coating robot provided with a coating unit configured by a plurality of rotary atomizing type electrostatic coating machines horizontally arranged, and a coating control apparatus that controls the coating unit and the coating robot. A diameter of each of bells is 50 mm or less. The coating material discharge amount of each rotary atomizing type electrostatic coating machine is 400 cc/min or less. A coating distance between each bell and a surface to be coated of a workpiece is controlled between 50 mm to 150 mm. The coating material discharge amounts of the plurality of electrostatic coating machines are controlled for the respective coating machines. The control of the coating material discharge amounts includes a pause of coating material discharge.

Provided in certain embodiments herein are gas controlled electrospray systems and processes for manufacturing depositions, such as thin layer films. In some embodiments, processes and systems provided herein are suitable for and configured to manufacture uniform depositions, such as having uniform thickness.

Provided in certain embodiments herein are gas controlled electrospray systems and processes for manufacturing depositions, such as thin layer films. In some embodiments, processes and systems provided herein are suitable for and configured to manufacture uniform depositions, such as having uniform thickness.

An improved electro hydrodynamic method is provided. The method comprises arranging (11) an electro hydrodynamic device inside an enclosure and distributing (12) positive and/or negative ions inside the enclosure during a charging period with a certain defined amount of power. The distribution of the positive and/or the negative ions inside the enclosure (20) is performed so that a predefined amount of charge is set on the interior of the enclosure (20). Within a predetermined period of time after the charging period has ended, the electrospinning device is activated so as to create a product. Finally, the product is removed from the device. The present invention offers a solution for the problem of non-identical initial process conditions for an electro hydrodynamic process caused by any electric charges on the equipment.

An additive manufacturing process includes creating an aerosol from a powder at a spray generator, charging the aerosol to produce a charged aerosol having a first charge, forming a blanket charge on a deposition surface having a second charge with an opposite polarity from the first charge, selectively removing regions of the blanket charge, leaving charged regions on the deposition surface, and transporting the charged aerosol to the charged regions to form structures on the charged regions from the charged aerosol.

An additive manufacturing process includes creating an aerosol from a powder at a spray generator, charging the aerosol to produce a charged aerosol having a first charge, forming a blanket charge on a deposition surface having a second charge with an opposite polarity from the first charge, selectively removing regions of the blanket charge, leaving charged regions on the deposition surface, and transporting the charged aerosol to the charged regions to form structures on the charged regions from the charged aerosol.

Tunable thermoplastic polymer powder feedstock formulations and tunable conductive thermoplastic polymer powder feedstock formulations are disclosed for delivery to a high-velocity sprayer are presently disclosed, along with tunable coatings made from the disclosed formulations, and methods for delivering such tunable thermoplastic polymer coatings to substrates.

A method for forming a nanocomposite coating on a substrate is described. The nanocomposite substrate comprises polyethylene, functionalized carbon nanotubes, and nanoclay. The method may use microparticles of UHMWPE with functionalized carbon nanotubes and clay nanoplatelets to form a powder mixture, which is then applied to a heated substrate to form the nanocomposite coating. The nanocomposite coating may have a Vickers hardness of 10.5-12.5 HV and a debonding strength of at least 25 N.