A method of additive manufacturing includes forming a plurality of build layers, each of the plurality of build layers formed by transferring a first build material having a first particle size to form a first build material and transferring a second build material on the first build material to form one of the plurality of build layers, a particle size of the second build material is smaller than the first build material and each transfer step is performed by a xerographic engine. Each transfer step is involves transfer to a conveyor which can take the form of a belt or drum.

The present invention provides a method of forming a pattern that can form a precise pattern on a variety of media by using powders and provides a pattern-producing apparatus.

The method of forming a pattern includes providing a liquid pattern on a surface of a medium, applying a powder to the liquid pattern so as to adhere to the liquid pattern, removing the powdery particles of the powder not adhered to the liquid pattern to give a pattern of the powder, and further applying another powder to the pattern of the powder.

An electrophotography-based additive manufacturing system is used to print a three-dimensional part. An electrophotography engine is used to print a part layer of the three-dimensional part is using a part material compositionally including part material particles. The developed part layer is transferred from the electrophotography engine to a transfer medium, and the transferred part layer is transfused together to previously-printed layers using a layer transfusion assembly. A surface height profile of the transfused part layers is measured using a surface profilometer, and a thickness profile of a subsequently-printed part layer is controlled responsive to the measured surface height profile.

Provided is a light-absorbing material flying apparatus including: a light-absorbing material that absorbs light; and a light-absorbing material flying section configured to irradiate the light-absorbing material with an optical vortex laser beam corresponding to a light absorption wavelength of the light-absorbing material to fly the light-absorbing material by an energy of the optical vortex laser beam in a direction in which the optical vortex laser beam is emitted to attach the light-absorbing material on an attachment target.

A 3-D printer includes build and support material development stations that electrostatically transfer build material and support material to an ITB. The ITB transfers a layer of build and support material to a platen each time the platen contacts one of the layers on the ITB, to successively form a freestanding stack of the layers on the platen. A sensor is positioned to generate a topographic measurement of the layer on the platen, and an aerosol applicator is positioned to propel build and support material on to the layer on the platen. The aerosol applicator controls the build and support material being propelled, based on the topographic measurement from the sensor through a feedback loop, to adjust the amount and location of the build material and the support material propelled on to the layer, and thereby control the flatness of surface topology of the layers in the freestanding stack on the platen.

A three-dimensional (3-D) printer includes build and support material development stations positioned to transfer layers of build and support materials to an intermediate transfer surface. The intermediate transfer surface transfers a layer of the build and support materials to a platen each time the platen contacts the intermediate transfer surface. A sensor detects the thickness of the layer on the platen, and a mechanical planer is positioned to contact and level the layer on the platen as the platen moves past the mechanical planer. Additionally, a feedback loop is electrically connected to the sensor and the mechanical planer. The mechanical planer adjusts the amount of the build material and the support material removed from the layer based on the thickness of the layer on the platen, as determined by the sensor.

A three-dimensional (3-D) printer includes build and support material development stations positioned to transfer layers of build and support materials to an intermediate transfer surface. A platen having a flat surface is positioned to contact the intermediate transfer surface. The intermediate transfer surface transfers a layer of the build and support materials to the flat surface of the platen as the platen contacts one of the layers on the intermediate transfer surface. A dispenser is positioned to deposit a leveling material on the layer on the platen, and a mechanical planer is positioned to contact and level the leveling material on the layer on the platen to make the top of the leveling material parallel to the flat surface of the platen.

A supply station for dispensing build material from a build material container is provided. The supply station includes a stationary support structure supporting a cylindrical cage along an axis, wherein the cylindrical cage is configured to be rotated in a first angular direction to dispense build material from the build material container.

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.

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.