SYSTEMS AND METHODS FOR ELECTROPHOTOGRAPHY-BASED ADDITIVE MANUFACTURING OF PARTS UTILIZING MULTIPLE PRINTING PATHS

1 . An electrostatographic based additive manufacturing system for printing three-dimensional parts, the additive manufacturing system comprising:

a first imaging engine configured to develop imaged layers of a thermoplastic-based powder;

a first transfer medium configured to receive the imaged layers from the first imaging engine;

a first transfusion assembly configured to transfuse imaged layers from the first transfer medium onto part build surfaces by pre-heating an imaged layer on the first transfer medium and applying pressure to transfuse the pre-heated imaged layer onto a part build surface;

a first platen configured to have a first part formed thereon;

a second platen configured to have a second part formed thereon; and

a part transport system providing part paths, the part transport system configured to move the first platen and the second platen proximate the first transfusion assembly in an alternating pattern such that the first part and the second part are each acted on by the first transfusion assembly to have imaged layers transferred thereto to build the first part and the second part in parallel.

2 . The electrostatographic based additive manufacturing system of claim 1 , wherein part transport system includes at least one track providing the part paths.

3 . The electrostatographic based additive manufacturing system of claim 1 , and further comprising:

a second imaging engine configured to develop imaged layers of the thermoplastic-based powder;

a second transfer medium configured to receive the imaged layers from the second imaging engine;

a second transfusion assembly configured to transfuse imaged layers from the second transfer medium onto part build surfaces by pre-heating an imaged layer on the second transfer medium and applying pressure to transfuse the pre-heated imaged layer onto a part build surface;

wherein the part transport system is configured to move the first platen and the second platen proximate the first transfusion assembly and proximate the second transfusion assembly in an alternating pattern such that the first part and the second part are each acted on by the first transfusion assembly and the second transfusion assembly to have imaged layers transferred thereto to build the first part and the second part in parallel.

4 . The electrostatographic based additive manufacturing system of claim 1 , and further comprising a plurality of decoupled processing stations, wherein the part transport system is configured to move the first platen and the second platen proximate the plurality of decoupled processing stations such that the first part and second part are built in parallel at the plurality of decoupled processing stations.

5 . The electrostatographic based additive manufacturing system of claim 1 , wherein the part transport system includes a gantry with a single x-stage having at least two x-stage actuators each configured to move a different one of the first platen and the second platen under the first transfusion assembly.

6 . The electrostatographic based additive manufacturing system of claim 1 , wherein the part transport system includes a gantry with a first x-stage and a second x-stage each configured to move a different one of the first platen and the second platen in the x-direction, the system configured to move the first and second x-stages in a y-direction such that the first x-stage is positioned proximate the first transfusion assembly and then the second x-stage is positioned proximate the first transfusion assembly.

7 . The electrostatographic based additive manufacturing system of claim 6 , wherein the first x-stage and the second x-stage are mounted in parallel.

8 . The electrostatographic based additive manufacturing system of claim 1 , wherein the part transport system includes a track along which the first platen and the second platen move in both an x-direction and a y-direction perpendicular to the x-direction.

9 . The electrostatographic based additive manufacturing system of claim 8 , and further comprising a single z-stage configured to move the track in a z-direction perpendicular to the x-direction and the y-direction.

10 . The electrostatographic based additive manufacturing system of claim 8 , and further comprising a plurality of z-stages each configured to move a different one of the plurality of platens in a z-direction, perpendicular to the x-direction and the y-direction, relative to the track.

11 . The electrostatographic based additive manufacturing system of claim 1 , wherein the first transfusion assembly comprises a pre-transfusion heater, a pressing component, and a post-transfusion cooler.

12 . A method for printing a three-dimensional part with an electrostatographic based additive manufacturing system, the method comprising:

developing layers of a powder material using at least one electrostatographic engine;

transferring the developed layers from the at least one electrostatographic engine to a transfer medium;

using a transport system to move a first platen proximate a first transfusion assembly;

using the first transfusion assembly to transfuse one of a plurality of imaged layers from the first transfer medium onto a part build surface of a first part on the first platen;

using the transport system to move a second platen proximate the first transfusion assembly;

using the first transfusion assembly to transfuse another of the plurality of imaged layers from the first transfer medium onto a part build surface of a second part on the second platen such that the first part and the second part are built in parallel.

13 . The method of claim 12 , and further comprising alternating, for subsequent layers of the plurality of imaged layers, using the transport system to move the first platen proximate the first transfusion assembly and using the first transfusion assembly to transfuse a subsequent one of the plurality of imaged layers from the first transfer medium onto the part build surface of the first part on the first platen with using the transport system to move the second platen proximate the first transfusion assembly and using the first transfusion assembly to transfuse a subsequent one of the plurality of imaged layers from the first transfer medium onto the part build surface of the second part on the second platen such that the first part and the second part are built in parallel.

14 . The method of claim 12 , wherein using the first transfusion assembly to transfuse the one of the plurality of imaged layers from the first transfer medium onto the part build surface of the first part on the first platen further comprises pre-heating the one of the plurality of imaged layers on the first transfer medium and applying pressure to transfuse the pre-heated one of the plurality of imaged layers onto the part build surface of the first part.

15 . An electrostatographic based additive manufacturing system for printing three-dimensional parts, the additive manufacturing system comprising:

a first imaging engine configured to develop imaged layers of a thermoplastic-based powder on a part build surface;

a first transfusion assembly configured to transfuse imaged layers on the part build surfaces by heating an imaged layer on the part build surface and applying pressure to transfuse the heated imaged layer into the part build surface;

a first platen configured to have a first part formed thereon;

a second platen configured to have a second part formed thereon; and

a part transport system providing part paths, the part transport system configured to move the first platen and the second platen proximate the first imaging engine and the first transfusion assembly in an alternating pattern such that the first part and the second part are each acted on by the first imaging engine and the first transfusion assembly to have imaged layers transferred thereto to build the first part and the second part in parallel.