REGISTRATION AND OVERLAY ERROR CORRECTION OF ELECTROPHOTOGRAPHICALLY FORMED ELEMENTS IN AN ADDITIVE MANUFACTURING SYSTEM

摘要

In a method for printing a three-dimensional (3D) parts with an additive manufacturing system, a developed layer of an electrically charged powder material is produced on a transfer medium using an electrophotographic (EP) engine. The transfer medium and the developed layer are fed in a feed direction. A position of the developed layer on the transfer medium is detected using a first sensor having a first output that indicates the position. A position of a moveable build platform is adjusted relative to the transfer medium to reduce one or more overlay errors between the developed layer and an intermediate build surface of a three-dimensional structure retained on the moveable build platform based on the first output. The developed layer is transferred to the intermediate build surface using a pressing element.

主权项

1. A method for printing three-dimensional (3D) parts with an additive manufacturing system, the method comprising:
producing a first developed layer of an electrically charged powder material on a transfer medium using a first electrophotographic (EP) engine; feeding the transfer medium and the developed layer in a feed direction; detecting a position of the first developed layer on the transfer medium using a first sensor, the first sensor having an output indicating the position; adjusting a position of a moveable build platform relative to the transfer medium to reduce one or more overlay errors between the first developed layer and an intermediate build surface of a three-dimensional structure retained on the moveable build platform based on the first output, using a controller; and transferring the first developed layer to the intermediate build surface comprising pressing the first developed layer against the intermediate build surface using a pressing element.