Printing assembly and method of use thereof

Abstract

An apparatus comprising: a print head (154) including a plurality of ejection nozzles (158) spaced apart from one another, wherein a distance from a first ejection nozzle to a second ejection nozzle positioned adjacent to the first ejection nozzle defines an ejection pitch; a print head position control assembly including a first actuator assembly (102) to move the print head along a longitudinal axis and a second actuator assembly (103) to move the print head along a latitudinal axis; and a control unit communicatively coupled with the print head position control assembly. The control unit causes the ejection nozzles to dispense a plurality of drops of adhesive (50) while the print head traverses a first travel trajectory along the longitudinal axis in a first direction, indexes the print head along the latitudinal axis to a second travel trajectory, and causes the ejection nozzles to dispense a plurality of drops of adhesive while the print head traverses the second travel trajectory along the longitudinal axis in a second direction.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 62 / 851,957, filed May 23, 2019, entitled “Printing Component and Method of Using Therewith,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to printing components, and more specifically, to printing components for manufacturing equipment and methods of using them. Background Technology

[0004] Printed components can be used to "build" objects, such as 3D objects or parts, from building materials in a layered manner. Early iterations of printed components were used to prototype 3D parts. However, with improvements in printed component technology, there has been growing interest in using printed components for large-scale commercial production of parts. Problems in scaling printed components to commercial production may include, but are not limited to, improving the throughput of printed components to meet commercial demands, increasing the resolution quality and print performance of printed components in terms of yield, and dynamically adjusting the resolution or amount of material placed from the printed component during an effective printing cycle.

[0005] Generally, printing components used in various contexts (including, for example, manufacturing applications, inkjet printing applications, and other printing types) include issues parallel to those described above. For instance, manufacturing equipment typically includes a printing component, also known as a printhead assembly, which deposits material during the manufacturing process via an array of jet nozzles. Since each corresponding image pixel of the printed part typically receives material from a single corresponding jet nozzle, interruptions in the deposition process can lead to defects in the parts built by the equipment. Interruptions in material deposition can be caused by various reasons, such as nozzle misfires or blockages.

[0006] Therefore, there is a demand for alternative printed components and parts that can increase manufacturing throughput. Summary of the Invention

[0007] A first aspect Al includes a print assembly comprising a first printhead row comprising a first plurality of printheads sequentially spaced apart from one another in a direction transverse to a working axis, each of the first plurality of printheads comprising a plurality of nozzles. The print assembly comprises a second printhead row comprising a second plurality of printheads sequentially spaced apart from one another in the direction transverse to the working axis, each of the second plurality of printheads comprising a plurality of nozzles, wherein the first printhead row and the second printhead row are spaced apart along the working axis. The print assembly further comprises an actuator coupled to a first printhead of the first plurality of printheads, the actuator configured to move the first printhead relative to at least one second printhead of the second plurality of printheads in the direction transverse to the working axis.

[0008] A second aspect A2 includes the print assembly of the first aspect Al, wherein the actuator is coupled to the first plurality of printheads and is configured to move the first plurality of printheads uniformly relative to the second printheads of the second plurality of printheads in the direction transverse to the working axis.

[0009] A third aspect A3 includes the print assembly of any of the preceding aspects Al-A2, further comprising a second actuator coupled to a second printhead of the second plurality of printheads, the second actuator configured to move the second printhead relative to the first printhead in the direction transverse to the working axis.

[0010] A fourth aspect A4 includes the print assembly of any of the preceding aspects Al-A3, wherein the actuator is coupled to the first plurality of printheads and is configured to move the first plurality of printheads uniformly relative to the second plurality of printheads in the direction transverse to the working axis.

[0011] A fifth aspect A5 includes the print assembly of any of the preceding aspects Al-A4, further comprising a second actuator coupled to the second plurality of printheads and configured to move the second plurality of printheads uniformly relative to the first plurality of printheads in the direction transverse to the working axis.

[0012] A sixth aspect A6 includes the print assembly of any of the preceding aspects Al-A5, wherein the actuator is configured to move the first printhead such that a spacing between the first printhead and an adjacent printhead of the first printhead row is changed.

[0013] A seventh aspect A7 includes the print assembly of any of the preceding aspects Al-A6, wherein the actuator is further configured to move the first printhead such that a height between the first printhead and a platform is changed.

[0014] Eighth aspect A8 includes the printing assembly of any of the preceding aspects Al-A7, wherein the actuator is one of a plurality of actuators, wherein each of the plurality of actuators is coupled to one of the first plurality of printheads such that each of the first plurality of printheads is movable relative to a second one of the second plurality of printheads.

[0015] Ninth aspect A9 includes the printing assembly of any of the preceding aspects Al-A8, further comprising a third printhead row comprising a third plurality of printheads sequentially spaced apart from one another in a direction transverse to the working axis, each of the third plurality of printheads comprising a plurality of nozzles.

[0016] Tenth aspect A10 includes the printing assembly of any of the preceding aspects Al-A9, further comprising a second actuator coupled to a second printhead of the second plurality of printheads, the second actuator configured to move the second printhead relative to the first printhead in a direction transverse to the working axis.

[0017] Eleventh aspect Al l includes the printing assembly of any of the preceding aspects Al-A10, further comprising a third actuator coupled to a third printhead of the third plurality of printheads, the third actuator configured to move the third printhead relative to at least the second printhead row in a direction transverse to the working axis, wherein the second printhead row is disposed between the first printhead row and the third printhead row.

[0018] Twelfth aspect A12 includes the printing assembly of any of the preceding aspects Al-A11, further comprising a third actuator coupled to a third printhead of the third plurality of printheads, the third actuator configured to move the third printhead relative to the first printhead in a direction transverse to the working axis, wherein the second printhead row is disposed between the first printhead row and the third printhead row, and wherein the printheads of the second plurality of printheads are fixed relative to the first and third pluralities of printheads.

[0019] Thirteenth aspect A13 includes the printing assembly of any of the preceding aspects Al-A12, wherein the first printhead row is disposed between the second printhead row and the third printhead row, and wherein the printheads of the second and third pluralities of printheads are fixed relative to the first printhead row.

[0020] Fourteenth aspect A14 includes the printing assembly of any of the preceding aspects Al-A13, wherein the actuator is a fine actuator configured to move the first printhead relative to the second printhead in a direction transverse to the working axis at a fine motion resolution.

[0021] Fifteenth aspect A15 includes the printing assembly of any of the preceding aspects Al-A14, wherein the actuator is a coarse actuator configured to move the first print head relative to the second print head in a direction transverse to the working axis at a coarse motion resolution.

[0022] Sixteenth aspect A16 includes the printing assembly of any of the preceding aspects Al-A15, wherein the actuator is further configured to rotate the first print head about a vertical axis transverse to the printing direction.

[0023] Seventeenth aspect A17 includes the printing assembly of any of the preceding aspects Al-A16, wherein at least one print head of the first plurality of print heads overlaps at least one print head of the second plurality of print heads in a direction of the working axis.

[0024] Eighteenth aspect A18 includes the printing assembly of any of the preceding aspects Al-A17, further comprising a control system communicatively coupled to the actuator, the control system including a processor and a non-transitory memory storing computer-readable and executable instructions that, when executed by the processor, cause the control system to: map pixels of a print layer to a set of nozzles of the print head; send a signal to the actuator to move the first print head relative to the second print head in a direction transverse to the working axis; and after the first print head is moved, remap each pixel of the print layer to a different set of nozzles of the print head.

[0025] Nineteenth aspect A19 includes a manufacturing apparatus comprising: a build area; a printing assembly; and an actuator assembly to move the printing assembly relative to the build area in a direction along a working axis, wherein the printing assembly comprises: a support carriage; a first print head row comprising a first plurality of print heads sequentially spaced apart from one another in a direction transverse to the working axis; a second print head row comprising a second plurality of print heads sequentially spaced apart from one another in the direction transverse to the working axis, wherein the first print head row and the second print head row are spaced apart along the working axis; and an actuator coupled to a first print head of the first plurality of print heads, the actuator configured to move the first print head relative to the support carriage in the direction transverse to the working axis.

[0026] Twentieth aspect A20 includes the manufacturing apparatus of the nineteenth aspect A19, further comprising a fluid reservoir, wherein: each of the first plurality of print heads comprises a plurality of nozzles in fluid communication with the fluid reservoir; and each of the second plurality of print heads comprises a plurality of nozzles in fluid communication with the fluid reservoir.

[0027] Twenty-first aspect A21 includes the manufacturing apparatus of any of the preceding aspects A19-A20, further comprising a first fluid reservoir comprising a first material and a second fluid reservoir comprising a second material different from the first material, wherein: each of the first plurality of print heads comprises a plurality of nozzles in fluid communication with the first fluid reservoir; and each of the second plurality of print heads comprises a plurality of nozzles in fluid communication with the second fluid reservoir.

[0028] Twenty-second aspect A22 includes the manufacturing apparatus of any of the preceding aspects A19-A21, further comprising a first fluid reservoir comprising a first material and a second fluid reservoir comprising a second material different from the first material, wherein: a plurality of nozzles in a first subset of the first plurality of print heads are in fluid communication with the first fluid reservoir; and a plurality of nozzles in a second subset of the first plurality of print heads are in fluid communication with the second fluid reservoir, wherein the first subset of the first plurality of print heads is different from the second subset of the first plurality of print heads.

[0029] Twenty-third aspect A23 includes the manufacturing apparatus of any of the preceding aspects A19-A22, wherein the actuator is coupled to the first plurality of print heads and is configured to move the first plurality of print heads uniformly relative to the support carriage in a direction transverse to the working axis.

[0030] Twenty-fourth aspect A24 includes the manufacturing apparatus of any of the preceding aspects A19-A23, further comprising: a second actuator coupled to a second print head of the second plurality of print heads, the second actuator configured to move the second print head relative to the support carriage in a direction transverse to the working axis.

[0031] Twenty-fifth aspect A25 includes the manufacturing apparatus of any of the preceding aspects A19-A24, wherein the actuator is coupled to the first plurality of print heads and is configured to move the first plurality of print heads uniformly relative to the support carriage in a direction transverse to the working axis, the print assembly further comprising: a second actuator coupled to the second plurality of print heads and configured to move the second plurality of print heads uniformly relative to the support carriage in a direction transverse to the working axis.

[0032] A twenty-sixth aspect A26 includes a method comprising: moving, with an actuator assembly, a print assembly relative to a build area in a direction along a working axis, the print assembly comprising: a first print head row comprising a first plurality of print heads sequentially spaced apart from one another in a direction transverse to the working axis, and a second print head row comprising a second plurality of print heads sequentially spaced apart from one another in the direction transverse to the working axis, wherein the first print head row and the second print head row are spaced apart along the working axis: depositing material with the print assembly as the print assembly is moved in the direction along the working axis; moving the first print head row relative to a support carriage in the direction transverse to the working axis; and after moving the first print head row relative to the support carriage, moving the print assembly along the working axis and depositing additional material with the print assembly.

[0033] A twenty-seventh aspect A27 includes the method of the twenty-sixth aspect A26, wherein, prior to moving the first print head row relative to the support carriage, the print assembly deposits material as the print assembly is moved in a forward direction along the working axis; and after moving the first print head row relative to the support carriage, the print assembly deposits material with the print assembly as the print assembly is moved in an opposite direction along the working axis opposite the forward direction.

[0034] A twenty-eighth aspect A28 includes the method of any of the preceding aspects A16-A27, wherein, prior to moving the first print head row relative to the support carriage, the print assembly deposits material as the print assembly is moved in a forward direction along the working axis with the print assembly in a first pass, and after moving the first print head row relative to the support carriage, the print assembly deposits material as the print assembly is moved in the forward direction along the working axis with the print assembly in a second pass.

[0035] A twenty-ninth aspect A29 includes the method of any of the preceding aspects A16-A28, wherein the first print head row is moved relative to the support carriage such that a spacing between the plurality of nozzles of the first plurality of print heads of the first print head row and the plurality of nozzles of the second plurality of print heads of the print head row changes in the direction transverse to the working axis.

[0036] A thirtieth aspect A30 includes the method of any of the preceding aspects A16-A29, wherein the first print head row is moved relative to the support carriage such that a spacing between the plurality of nozzles of the first plurality of print heads of the first print head row and the plurality of nozzles of the second plurality of print heads of the second print head row changes in the direction transverse to the working axis in a random manner.

[0037] The thirty-first aspect A31 includes the method of any of the preceding aspects A16-A30, further comprising monitoring, by the control system, the print assembly depositing material as the print assembly moves in the direction along the working axis, wherein in response to the control system determining an error in the print assembly depositing material, the first printhead row is moved relative to the support carriage such that the first printhead row remains stationary until the error is determined by the control system.

[0038] The thirty-second aspect A32 includes the method of any of the preceding aspects A16-A31, further comprising communicating a signal from the control system to the print assembly upon determining the error, thereby initiating movement of the first printhead row relative to the support carriage in the direction transverse to the working axis.

[0039] The thirty-third aspect A33 includes the method of any of the preceding aspects A16-A32, wherein the first printhead row is moved relative to the support carriage such that a degree of overlap between the first plurality of printheads of the first printhead row and the second plurality of printheads of the second printhead row changes in the direction transverse to the working axis.

[0040] The thirty-fourth aspect A34 includes the method of any of the preceding aspects A16-A33, wherein prior to moving the first printhead row relative to the support carriage, the first material is deposited from the first subset of printheads onto the first set of pixels as the print assembly moves in the direction along the working axis.

[0041] The thirty-fifth aspect A35 includes the method of any of the preceding aspects A16-A34, wherein prior to moving the first printhead row relative to the support carriage, the second material is deposited from the second subset of printheads onto the second set of pixels as the print assembly moves in the direction along the working axis.

[0042] The thirty-sixth aspect A36 includes the method of any of the preceding aspects A16-A35, wherein after moving the first printhead row relative to the support carriage, the first material is deposited from the first subset of printheads onto the second set of pixels; and after moving the first printhead row relative to the support carriage, the second material is deposited from the first subset of printheads onto the first set of pixels.

[0043] The thirty-seventh aspect A37 includes the method of any of the preceding aspects A16-A36, wherein the first printhead row is moved relative to the support carriage in the direction transverse to the working axis based on a signal output by at least one sensor.

[0044] The thirty-eighth aspect A38 includes the method of any of the preceding aspects A16-A37, wherein the first printhead row is moved relative to the support carriage in the direction transverse to the working axis based on a geometry of a pattern to be printed.

[0045] A thirty-ninth aspect A39 includes a manufacturing apparatus comprising: a print head comprising a plurality of ejection nozzles, the plurality of ejection nozzles spaced apart from one another in a direction transverse to a longitudinal axis, wherein a distance from a first ejection nozzle of the plurality of ejection nozzles to a second ejection nozzle positioned adjacent to the first ejection nozzle defines an ejection pitch; a print head position control assembly comprising a first actuator assembly configured to move the print head along the longitudinal axis and a second actuator assembly configured to move the print head along a latitudinal axis; and an electronic control unit communicatively coupled with the print head position control assembly, the electronic control unit configured to: cause a selected ejection nozzle of the plurality of ejection nozzles to dispense more than one drop of binding agent while the print head traverses a first travel trajectory along the longitudinal axis in a first direction; index the print head along the latitudinal axis to a second travel trajectory by an index distance that is greater than zero and less than the ejection pitch; and cause the selected ejection nozzle of the plurality of ejection nozzles to dispense more than one drop of binding agent while the print head traverses the second travel trajectory along the longitudinal axis in a second direction opposite the first direction.

[0046] A fortieth aspect A40 includes the manufacturing apparatus of the thirty-ninth aspect A39, wherein the plurality of drops of binding agent are dispensed within a pixel defining a 2-dimensional spatial portion of a layer of build material traversed by the print head.

[0047] A forty-first aspect A41 includes the manufacturing apparatus of the fortieth aspect A40, wherein drop volumes of the plurality of drops of binding agent dispensed within the pixel are different.

[0048] A forty-second aspect A42 includes the manufacturing apparatus of the fortieth aspect A40, wherein drop volumes of the plurality of drops of binding agent dispensed within the pixel and locations within the pixel are different.

[0049] A forty-third aspect A43 includes the manufacturing apparatus of any of the preceding aspects A40-A42, wherein a total amount of binding agent predefined for dispensing within the pixel is dispensed over at least two passes of the print head as a fraction of the total amount of binding agent.

[0050] A forty-fourth aspect A44 includes the manufacturing apparatus of any of the preceding aspects A40-A43, wherein the index distance is half of the ejection pitch.

[0051] A forty-fifth aspect A45 includes the manufacturing apparatus of any of the preceding aspects A40-A44, wherein the index distance is an integer multiple of a fractional value of the ejection pitch.

[0052] Forty-sixth aspect A46 includes the manufacturing apparatus of any of the preceding aspects A40-A45, wherein the print head comprises a first print head row, the first print head row comprising a plurality of print heads, the plurality of print heads being spaced apart from one another in a direction transverse to the working axis, the manufacturing apparatus further comprising: an actuator coupled to a first print head of the plurality of print heads, the actuator configured to move the first print head along the weft axis.

[0053] Forty-seventh aspect A47 includes the manufacturing apparatus of the forty-sixth aspect A46, wherein the electronic control unit is further configured to index one or more of the plurality of print heads along the weft axis to a second pass trajectory at an index distance greater than zero and less than the ejection pitch.

[0054] Forty-eighth aspect A48 includes the manufacturing apparatus of the forty-seventh aspect A47, wherein the actuator is one of a plurality of actuators, wherein each of the plurality of actuators is coupled to a print head of the plurality of print heads.

[0055] Forty-ninth aspect A49 includes a manufacturing apparatus comprising: at least one print head comprising a plurality of ejection nozzles, the plurality of ejection nozzles being spaced apart from one another in a direction transverse to a longitudinal axis, wherein a distance from a first ejection nozzle of the plurality of ejection nozzles to a second ejection nozzle positioned adjacent to the first ejection nozzle defines an ejection pitch; a print head position control assembly comprising a first actuator configured to move the print head along the longitudinal axis and a second actuator configured to move the print head along a weft axis; and an electronic control unit communicatively coupled with the print head position control assembly, the electronic control unit configured to: cause a selected ejection nozzle of the plurality of ejection nozzles to dispense one or more drops of a binding agent to a layer of powder in a deposition pattern defined by a slicing engine as the print head traverses the layer of powder along the longitudinal axis, wherein the first ejection nozzle of the plurality of ejection nozzles corresponds to a first trajectory assigned by the slicing engine; index the print head along the weft axis by an index distance such that the first ejection nozzle corresponds to a second pass trajectory and another ejection nozzle corresponds to the first trajectory assigned by the slicing engine; and cause the indexed print head to traverse along the longitudinal axis and apply the binding agent to the layer of powder in the deposition pattern defined by the slicing engine.

[0056] Fiftieth aspect A50 includes the manufacturing apparatus of the forty-ninth aspect A49, wherein the step of indexing the print head along the weft axis occurs between a first pass and a second pass on the same layer of powder.

[0057] Fifty-first aspect A51 includes the manufacturing apparatus of any of the preceding aspects A49-A50, wherein the step of indexing the print head along the weft axis occurs after the binding agent is applied to a first layer of powder and before the binding agent is applied to a subsequent layer of powder.

[0058] A fifty-second aspect A52 includes the manufacturing apparatus of any one of aspects A49-A51, further comprising an in-situ monitoring system configured to: determine a malfunction of one or more of the plurality of jetting nozzles, and provide a notification signal to the electronic control unit identifying the one or more malfunctioning jetting nozzles.

[0059] A fifty-third aspect A53 includes the manufacturing apparatus of aspect A52, wherein the electronic control unit is further configured to: develop one or more indexing commands for indexing the printhead between predefined passes such that the malfunctioning jetting nozzles are configured to not traverse the same trajectory during a subsequent pass while being determined to be in a malfunctioning state.

[0060] A fifty-fourth aspect A54 includes the manufacturing apparatus of aspect A52, the electronic control unit is further configured to: develop one or more indexing commands for indexing the printhead between predefined passes such that the malfunctioning jetting nozzles do not traverse a trajectory that defines an edge of a deposition pattern for the printed part.

[0061] A fifty-fifth aspect A55 includes the manufacturing apparatus of any one of aspects A49-A54, wherein the slicing engine defines at least a predetermined number of layers and a deposition pattern of the binding agent for the printed part.

[0062] A fifty-sixth aspect A56 includes the manufacturing apparatus of any one of aspects A49-A55, further comprising: wherein the printhead comprises a first printhead row, the first printhead row comprising a plurality of printheads, the plurality of printheads being spaced apart from each other in a direction transverse to the working axis; and an actuator coupled to a first printhead of the plurality of printheads, the actuator configured to move the first printhead along a weft axis.

[0063] A fifty-seventh aspect A57 includes the manufacturing apparatus of aspect A56, wherein the electronic control unit is further configured to: index one or more of the plurality of printheads along the weft axis to a second pass trajectory by an indexing distance along the weft axis such that a first jetting nozzle corresponds to the second pass trajectory and another jetting nozzle corresponds to a first trajectory assigned by the slicing engine.

[0064] A fifty-eighth aspect A58 includes the manufacturing apparatus of aspect A56, wherein the actuator is one of a plurality of actuators, wherein each actuator of the plurality of actuators is coupled to a printhead of the plurality of printheads.

[0065] Fifty-ninth aspect A59 includes a manufacturing apparatus comprising: a print head comprising a plurality of ejection nozzles, the plurality of ejection nozzles spaced apart from one another in a direction transverse to a longitudinal axis; a print head position control assembly comprising a first actuator configured to move the print head along the longitudinal axis; and, an electronic control unit communicatively coupled with the print head position control assembly, the electronic control unit configured to: cause a selected ejection nozzle of the plurality of ejection nozzles to dispense a predetermined volume of adhesive in a deposition pattern defined by a slicing engine as the print head traverses the longitudinal axis to apply the adhesive to a powder layer, wherein an amount of adhesive dispensed in a vertically successive portion of the powder in a subsequent layer is gradually increased.

[0066] Sixty-first aspect A61 includes the manufacturing apparatus of any of preceding aspects A59-A60, wherein the amount of adhesive dispensed in the vertically successive portion of the powder in the subsequent layer is gradually increased beyond a decay length defined by the predetermined number of layers of powder.

[0067] Sixty-first aspect A61 includes the manufacturing apparatus of any of preceding aspects A59-A60, wherein the amount of adhesive dispensed in the vertically successive portion of the powder in the subsequent layer is gradually increased beyond a decay length defined by the predetermined number of layers of powder.

[0068] Sixty-first aspect A61 includes the manufacturing apparatus of any of preceding aspects A59-A60, wherein the amount of adhesive dispensed in the vertically successive portion of the powder in the subsequent layer is gradually increased beyond a decay length defined by the predetermined number of layers of powder.

[0069] Sixty-first aspect A61 includes the manufacturing apparatus of any of preceding aspects A59-A60, wherein the amount of adhesive dispensed in the vertically successive portion of the powder in the subsequent layer is gradually increased beyond a decay length defined by the predetermined number of layers of powder.

[0070] Sixty-first aspect A61 includes the manufacturing apparatus of any of preceding aspects A59-A60, wherein the amount of adhesive dispensed in the vertically successive portion of the powder in the subsequent layer is gradually increased beyond a decay length defined by the predetermined number of layers of powder.

[0071] Sixty-first aspect A61 includes the manufacturing apparatus of any of preceding aspects A59-A60, wherein the amount of adhesive dispensed in the vertically successive portion of the powder in the subsequent layer is gradually increased beyond a decay length defined by the predetermined number of layers of powder.

[0072] According to another embodiment, a manufacturing apparatus includes a build area, a print assembly, and an actuator assembly to move the print assembly relative to the build area in a direction along a working axis. The print assembly includes a support carriage, a first print head row including a first plurality of print heads sequentially spaced apart from one another in a direction transverse to the working axis, and a second print head row including a second plurality of print heads sequentially spaced apart from one another in the direction transverse to the working axis. The first print head row and the second print head row are spaced apart along the working axis. The print assembly further includes an actuator coupled with a first print head of the first plurality of print heads, the actuator configured to move the first print head relative to the support carriage in the direction transverse to the working axis.

[0073] According to another embodiment, a method includes moving, with an actuator assembly, a print assembly relative to a build area in a direction along a working axis. The print assembly includes a first print head row including a first plurality of print heads sequentially spaced apart from one another in a direction transverse to the working axis, and a second print head row including a second plurality of print heads sequentially spaced apart from one another in the direction transverse to the working axis. The first print head row and the second print head row are spaced apart along the working axis. The method includes depositing, with the print assembly, a material while the print assembly is moving in the direction along the working axis, moving the first print head row relative to a support carriage in the direction transverse to the working axis, and after moving the first print head row relative to the support carriage, moving the print assembly along the working axis and depositing, with the print assembly, an additional material.

[0074] Additional features and advantages of the manufacturing apparatuses and components thereof described herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art who practice the embodiments described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0075] It is to be understood that the foregoing general description and the following detailed description are intended to provide an overview or framework for understanding the nature and character of the subject matter claimed. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated and constitute part of this specification. The drawings illustrate the various embodiments described herein and, together with the description, serve to explain principles and operations of the claimed subject matter. BRIEF DESCRIPTION OF DRAWINGS

[0076] FIG. 1A depicts an illustrative process flow diagram for building a component using a manufacturing apparatus and manufacturing method according to one or more embodiments shown and described herein;

[0077] FIG. 1BA manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted;

[0078] FIG. 1C Another manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted;

[0079] FIG. 1D An enlarged view of a build material of a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted;

[0080] FIG. 2 An embodiment of a print assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, the print assembly having a pair of printhead rows;

[0081] FIG. 3 An embodiment of a print assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, the print assembly having a pair of printhead rows including a plurality of printheads;

[0082] FIG. 4 An embodiment of a print assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, the print assembly having a first printhead movable laterally;

[0083] FIG. 5 An embodiment of a print assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, the print assembly having a pair of printheads movable laterally;

[0084] FIG. 6 An embodiment of a print assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, the print assembly having a first printhead row of printheads movable laterally;

[0085] FIG. 7 An embodiment of a print assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, the print assembly having a pair of printhead rows movable laterally;

[0086] FIG. 8 An embodiment of a print assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, the print assembly having a pair of printheads movable;

[0087] FIG. 9 An embodiment of a print assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, the print assembly having a pair of printheads rotatable;

[0088] FIG. 10 schematically depicts an embodiment of a print assembly for a manufacturing device with a pair of printheads positioned at a default elevation in accordance with one or more embodiments shown and described herein;

[0089] FIG. 11 schematically depicts an embodiment of a print assembly for a manufacturing device with a pair of printheads longitudinally movable relative to a default elevation in accordance with one or more embodiments shown and described herein;

[0090] FIG. 12 schematically depicts an embodiment of a print assembly for a manufacturing device with three rows of printheads in accordance with one or more embodiments shown and described herein;

[0091] FIG. 13 schematically depicts an embodiment of a print assembly for a manufacturing device with three rows of printheads movable in accordance with one or more embodiments shown and described herein;

[0092] FIG. 14 schematically depicts an embodiment of a print assembly for a manufacturing device with three printheads movable in respective rows in accordance with one or more embodiments shown and described herein;

[0093] FIG. 15 schematically depicts an embodiment of a print assembly for a manufacturing device with a pair of outer printhead rows movable relative to a fixed center row of printheads in accordance with one or more embodiments shown and described herein;

[0094] FIG. 16 schematically depicts an embodiment of a print assembly for a manufacturing device with a pair of outer printhead rows fixed relative to a movable center row of printheads in accordance with one or more embodiments shown and described herein;

[0095] FIG. 17A schematically depicts an embodiment of a print assembly for a manufacturing device with a first printhead row of printheads coupled to a fine actuator for moving the first printhead row in accordance with one or more embodiments shown and described herein;

[0096] FIG. 17B schematically depicts an embodiment of a print assembly for a manufacturing device with a first printhead row of printheads coupled to a fine actuator for moving the first printhead row in accordance with one or more embodiments shown and described herein;

[0097] FIG. 17CEmbodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, wherein a first printhead row of printheads is coupled to a fine actuator for moving the first printhead row;

[0098] FIG. 17D Embodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, wherein a first printhead row of printheads is coupled to a coarse actuator for moving the first printhead row;

[0099] FIG. 17E Embodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, wherein a first printhead row of printheads is coupled to a coarse actuator for moving the first printhead row;

[0100] FIG. 17F Embodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, wherein a first printhead row of printheads is coupled to a coarse actuator for moving the first printhead row;

[0101] FIG. 17G Embodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, wherein a first printhead row of printheads is coupled to a coarse actuator for moving the first printhead row;

[0102] FIG. 18A Embodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, wherein a first material is deposited from a pair of printhead rows along a first stroke;

[0103] FIG. 18B Embodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, FIG. 18A wherein a first material is deposited from a pair of printhead rows along a second stroke;

[0104] FIG. 19A Embodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, wherein a first material is deposited from a first printhead row of printheads and a second material is deposited from a second printhead row of printheads along a first stroke;

[0105] FIG. 19B Embodiments of a print assembly for a manufacturing device are illustratively depicted in accordance with one or more embodiments shown and described herein, FIG. 19A wherein a first material is deposited from a first printhead row of printheads and a second material is deposited from a second printhead row of printheads at different sites along a second stroke;

[0106] FIG. 20A An embodiment of a printing assembly for a manufacturing apparatus according to one or more embodiments shown and described herein is schematically depicted, wherein along a first stroke, a first material is deposited from a first printhead of a printhead and a second material is deposited from a second printhead of a printhead;

[0107] FIG. 20B The illustration schematically depicts one or more embodiments shown and described herein. FIG. 20A The printing assembly, wherein along a first stroke, a first material is deposited from a first printhead outlet of the printhead, and a second material is deposited from a second printhead outlet of the printhead;

[0108] FIG. 21A A printing assembly implementing a second actuator assembly according to one or more embodiments shown and described herein is schematically depicted for latitudinal axis rotation of the printing assembly;

[0109] FIG. 21B A schematic depiction of a fractional portion of the spray pitch shifted according to one or more embodiments shown and described herein. FIG. 21A Printing components;

[0110] FIG. 21C A top view depicting a build area according to one or more embodiments shown and described herein, in which subpixel transposition of the printhead is performed between a first stroke and a second stroke to deposit the binder across a layer of powder for increased resolution;

[0111] FIG. 21D A top view depicting a construction region according to one or more embodiments shown and described herein, the construction region covering according to FIG. 21C The design deposition pattern depicted in the image is a deposition pattern of adhesive applied to create the deposition pattern.

[0112] FIG. 21E Another illustrative construction region is depicted according to one or more embodiments shown and described herein, in which a combination of large and small droplets is used to distribute, for example, at different sites within a pixel. FIG. 21C The same amount of adhesive is used for each pixel depicted in the image.

[0113] FIG. 21F A top view depicting a construction region according to one or more embodiments shown and described herein, the construction region covering according to FIG. 21E The design deposition pattern depicted in the image is a deposition pattern of adhesive applied to create the deposition pattern.

[0114] FIG. 21GAn example depicting a deposition pattern of adhesive material on a build area using a combination of large and small droplets at a changeover site within a pixel, in accordance with one or more embodiments shown and described herein;

[0115] FIG. 22A Illustratively depicting a build area and a print assembly configured in a home position with a failed ejection port, in accordance with one or more embodiments shown and described herein;

[0116] FIG. 22B Illustratively depicting a build area and a print assembly configured in a shifted position with a failed ejection port, in accordance with one or more embodiments shown and described herein; FIG. 22A

[0117] FIG. 23A Depicting a model of a part for building having a downward facing surface, in accordance with one or more embodiments shown and described herein;

[0118] FIG. 23B Illustratively depicting a cross section of a model for building having a predefined adhesive dispensing to control adhesive bleed, in accordance with one or more embodiments shown and described herein; FIG. 23A

[0119] FIG. 24 Depicting a flowchart of an illustrative method of depositing material with a print assembly having a movable array of print heads, in accordance with one or more embodiments shown and described herein;

[0120] FIG. 25 Depicting a flowchart of an illustrative method of depositing material with a print assembly having a movable array of print heads, in accordance with one or more embodiments shown and described herein;

[0121] FIG. 26 Depicting a flowchart of an illustrative method of depositing material with a print assembly having a movable array of print heads, in accordance with one or more embodiments shown and described herein;

[0122] FIG. 27 Depicting a flowchart of an illustrative method of depositing material with a print assembly having a movable array of print heads, in accordance with one or more embodiments shown and described herein;

[0123] FIG. 28 Depicting a flowchart of an illustrative method of depositing material with a print assembly having a movable array of print heads, in accordance with one or more embodiments shown and described herein;

[0124] ​​FIG. 29 a flow diagram depicting an illustrative method of depositing material with a printing assembly having a movable row of printheads depositing a number of materials at different build sizes, in accordance with one or more embodiments shown and described herein;

[0125] FIG. 30 a flow diagram depicting an illustrative method of depositing material with a printing assembly having an indexable printing assembly providing sub-pixel jetting nozzle movement for high resolution material deposition, in accordance with one or more embodiments shown and described herein;

[0126] FIG. 31 a flow diagram depicting an illustrative method of depositing material with a printing assembly having an indexable printing assembly providing predefined random indexing of one or more of a plurality of jetting nozzles, in accordance with one or more embodiments shown and described herein; and

[0127] FIG. 32 a flow diagram depicting an illustrative method of controlling interlayer adhesive bleed, in accordance with one or more embodiments shown and described herein. DETAILED DESCRIPTION

[0128] Reference will now be made in detail to embodiments of manufacturing apparatuses, and components thereof, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. FIGS. 1A-1C One embodiment of a manufacturing apparatus is schematically depicted, the manufacturing apparatus including a printing assembly for depositing material. The printing assembly can generally include a support carriage, a first printhead row including a plurality of printheads arranged in sequence and spaced apart from one another in a direction transverse to a working axis of the apparatus. Each of the first plurality of printheads includes a plurality of jetting nozzles for depositing material.

[0129] The printing assembly can further include a second printhead row including a second plurality of printheads arranged in sequence and spaced apart from one another in a direction transverse to the working axis of the apparatus. Each of the second plurality of printheads includes a plurality of jetting nozzles for further depositing material. The first printhead row and the second printhead row are spaced apart along the working axis. The printing assembly can further include an actuator coupled with a first printhead of the first plurality of printheads, the actuator configured to move the first printhead relative to the support carriage in the direction transverse to the working axis of the apparatus.

[0130] Various embodiments of a print assembly for a manufacturing device, a manufacturing device including the print assembly, and methods of using the same are described in further detail herein with specific reference to the drawings. It should be understood that the embodiments of the manufacturing device shown and described herein can be configured and operable to build three-dimensional and / or non-three-dimensional objects or parts.

[0131] In the document, ranges can be expressed as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant, and that the ranges are only meant to be their literal limits.

[0132] Directional terms as used herein - such as up, down, right, left, front, back, top, upper, bottom and lower - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0133] Unless specifically stated otherwise, any methods described herein are not constrained to any particular order or sequence of steps. Unless specifically stated otherwise, the described embodiments are not constrained to any particular orientation of the components. Thus, unless specifically stated otherwise, no inference should be drawn from the mere use of a term in a certain way that the term is intended to connote anything other than its plain, ordinary meaning. No inference should be drawn that any aspect or component or step is critical, essential or necessary, or that the inclusion thereof renders the application not combinable with or insusceptible of combination with any other aspect or component or step. The terms "comprising," "including," containing" and like terms are used herein in their broadest sense and are used to mean that the claimed application can include additional aspects, components, steps, or the like not expressly stated in the claims. Thus, these terms are not used to limit or restrict the claimed application in any way.

[0134] As used herein, the singular forms "a", "an" and "the" include plural referents unless the context clearly indicates otherwise. Thus, for example, reference to "a" component includes aspects with two or more such components unless the context clearly indicates otherwise.

[0135] The embodiments described herein are directed to manufacturing equipment (e.g., additive manufacturing equipment) and components for manufacturing equipment, particularly print assemblies for depositing binder, build material (e.g., organic or inorganic powder), and / or other jettable composite materials in the manufacturing equipment. The embodiments described herein can be implemented to provide, for example, redundancy in material deposition, improved print resolution, dynamic material resolution adjustment, dynamic build size adjustment, and multi-material deposition by the manufacturing equipment to facilitate jet reliability and resolution by increasing the probability that each image pixel (e.g., DPI grid point) of a three-dimensional object built by the additive manufacturing process receives an appropriate amount of the material thereon. It should be appreciated that the degree of redundancy in the image transfer process is related to the number of dedicated jet nozzles available to deposit material for each image pixel. Further, it can be appreciated that the technology developed and described herein is related to the manufacturing industry, however, certain aspects of the technology can be applied to related industries, such as 2D printing, and the like.

[0136] Reference FIG. 1A depicts an illustrative process flow diagram for building a part 80 using the manufacturing equipment 100 and manufacturing method. FIG. 1A It is intended to provide a non-limiting overview of the manufacturing equipment 100 and manufacturing method described and detailed herein. The equipment 100 is configured to perform one or more predefined operations specified by build instructions executed by the control system 10.

[0137] As used herein, "build instructions" refer to control commands used to manipulate the operations of the equipment 100 to build the part 80. The build instructions define, for example, a deposition pattern for each layer of the part 80 to be built and a plurality of motion controls that specify commands that set forth the ordered operation of motors, actuators, print assemblies, jet nozzles, and various other components of the equipment to build the part 80. The build instructions are defined based on the part design or model and mechanical specifications of the equipment 100. For example, the equipment 100 can include a predefined and fixed distance between jet nozzles within a print head, referred to herein as "jet pitch." The embodiments described herein provide techniques for printing the part 80 using sub-jet pitch indexing to deliver a high distribution of binder that would not be achievable without reducing the jet pitch, thereby increasing the complexity and cost of the print head. In other words, for example, a print head having a jet pitch of 400 DPI (dots per inch) can achieve a binder deposition of greater than 400 DPI by the sub-jet pitch indexing described herein.

[0138] The equipment 100 further receives build material 40 and binder 50 that can be deposited layer-by-layer and drop-by-drop, respectively, in accordance with the build instructions for building the part 80. For example, the equipment 100 can deposit the build material 40 and binder 50 in the build area 120 FIG. 1B) to form a layer of powder 60 (also referred to herein as a layer of build material), and then depositing one or more drops of binder 70 within the pixel 20, thereby forming a voxel 30. The "build material" can include one or more organic and / or inorganic materials that, when combined with the binder and optionally an energy source, cure to form a portion of the part 80.

[0139] As used herein, a "pixel" refers to a two-dimensional spatial portion of an object or part to be printed by the apparatus 100, specifically, a current slice or layer of a three-dimensional part relative to its positioning along the build area. Each pixel corresponds to an image pixel defined in a design deposition pattern of the build instructions. An image pixel is a digital representation of a pixel. An image pixel includes a width defined by a jet spacing of a jetting nozzle of the apparatus 100. As used herein, a "voxel" refers to a 3-dimensional spatial portion of powder in the build area defined by one or more drops of binder deposited within a pixel of a current slice or layer forming a three-dimensional part, such as the part 80. It should be appreciated that a voxel can not be a cube, as the shape of the voxel depends on the wicking and curing behavior of the binder and build material, such as a layer of powder within which the binder is deposited.

[0140] The binder 50 can be deposited in various amounts at various sites within a layer of powder 60 (e.g., build material) in the form of micro-drops. The sites and amounts of the micro-drops are defined in a "design deposition pattern," which refers to a collection of image pixels forming a pattern of a desired slice of a build file and defines an "applied deposition pattern" when applied to a layer of powder 60 by the apparatus 100. While the design deposition pattern defines amounts (e.g., "drop volumes") and sites (e.g., central sites of micro-drops of binder on a layer of powder 60), the applied deposition pattern refers to the distribution of the binder through one or more layers of powder, which can include overlapping into adjacent pixels or lower layers of powder. (See FIG. 21D ). As used herein, a "drop volume" refers to the volume of a micro-drop of binder released from a jetting orifice at one time. For a single pixel, several drops can be released, and the drop volumes of the drops can vary. After a layer or layers of powder 60 are formed and one or more micro-drops of binder 50 are deposited, the apparatus 100 forms a part 80. More specific methods for forming the part 80, as well as embodiments of the apparatus 100, will now be described in detail.

[0141] Reference is now made to FIG. 1BFIG. 1 schematically depicts an embodiment of a conventional manufacturing apparatus 100. The apparatus 100 includes a cleaning station 108, a build area 120, a supply platform 130, a recoat assembly 140, and a print assembly 150. The recoat assembly 140 and the print assembly 150 are coupled to a rail 104 of the apparatus 100 and are configured to translate along the rail 104 in response to actuation of a first actuator assembly 102. In some embodiments, a vertical cross-section of the rail 104 (i.e., a cross-section in the Y-Z plane of the coordinate axes depicted in the figure) can be rectangular or square, while in other embodiments, the rail 104 can have an "I" configuration in the vertical cross-section (i.e., a cross-section in the Y-Z plane of the coordinate axes depicted in the figure). The first actuator assembly 102 can be configured to facilitate independent control of the recoat assembly 140 and the print assembly 150 along a working axis 116 of the apparatus 100. The working axis 116 is also referred to herein as a "longitudinal axis" (i.e., extending along the + / -X axis depicted in the figure). This allows the recoat assembly 140 and the print assembly 150 to traverse the working axis 116 of the apparatus 100 in the same direction and / or opposite directions, as well as at different speeds and / or the same speed. Independent actuation and control of the recoat assembly 140 and the print assembly 150, in turn, allows at least some steps of a manufacturing process (e.g., an additive manufacturing process) to be performed synchronously, thereby reducing the overall cycle time of the manufacturing process to less than the sum of the cycle times for each individual step. In other embodiments, the apparatus 100 can include additional actuator assemblies coupled to the recoat assembly 140, the print assembly 150, etc.

[0142] In some embodiments, the second actuator assembly 103 can be configured to facilitate independent control of the print assembly 150 along a latitudinal axis (i.e., extending along the + / -Y axis as depicted in the figure), which is generally perpendicular to the longitudinal axis (i.e., the working axis 116). As described in greater detail herein, the second actuator assembly 103 can provide fine movement of the print assembly 150 along the longitudinal axis, referred to herein as indexing. The first actuator assembly 102 and the second actuator assembly 103 are generally referred to as a print head position control assembly. That is, the print head position control assembly includes the first actuator assembly 102 configured to move the print head along the longitudinal axis and the second actuator assembly 103 configured to move the print head along the latitudinal axis. The print head position control assembly can be controlled via signals generated by a control system 10, such as an electronic control unit. The electronic control unit can include a processor and a non-transitory computer readable memory.

[0143] In some embodiments, the first actuator assembly 102 includes a position sensor 102a that provides position information of the recoat assembly 140 and / or the print assembly 150 in a feedback control signal to the electronic control unit, such that the electronic control unit can track the position of the recoat assembly 140 and / or the print assembly 150 in response to the provided control signal. In some instances, the electronic control unit can make adjustments to the control signal provided to the first actuator assembly 102 based on the position information provided by the position sensor. In embodiments, the position sensor can be an encoder, an ultrasonic sensor, an optical-based sensor, a magnetic force sensor, or the like, embedded or coupled to the first actuator assembly 102.

[0144] As noted above, in the embodiments described herein, both the recoat assembly 140 and the print assembly 150 are positioned on the working axis 116 of the apparatus 100. As such, movement of the recoat assembly 140 and the print assembly 150 along the working axis 116 occurs along the same axis, and thus are collinear. With this configuration, the recoat assembly 140 and the print assembly 150 can occupy the same space (or portions of the same space) along the working axis 116 of the apparatus 100 at different times during a single build cycle. In other embodiments, components of the manufacturing apparatus 100 (such as the recoat assembly 140, the print assembly 150, or the like) that traverse the working axis 116 need not be centered about the working axis 116. In this instance, at least two components of the manufacturing apparatus 100 are arranged relative to the working axis 116 such that the components can occupy the same or overlapping volumes along the working axis 116 as the components traverse the working axis 116.

[0145] The recoat assembly 140 is configured to facilitate distribution of build material 40 over the build area 120 and the supply platform 130. As will be described in greater detail herein, the print assembly 150 is configured to facilitate deposition of binder material 50 and / or other jettable constituent materials (e.g., ink, fluid medium, nanoparticles, fluorescent particles, sintering aids, anti-sintering aids, etc.) over the build area 120 as the print assembly 150 traverses the build area 120 along the working axis 116 of the apparatus 100. In the embodiment of the apparatus 100 described herein, the working axis 116 of the apparatus 100 is parallel to the + / - X axis of the coordinate axes depicted in the figures. In the embodiment described herein, the cleaning station 108, the build area 120, the supply platform 130, the recoat assembly 140, and the print assembly 150 are positioned in series along the working axis 116 of the apparatus 100 between a home position 151 of the print assembly 150 and a home position 153 of the recoat assembly 140, the home position 151 being located proximate one end of the working axis 116 in the -X direction, and the home position 153 being located proximate one end of the working axis 116 in the +X direction. That is, the home position 151 of the print assembly 150 and the home position 153 of the recoat assembly 140 are spaced apart from one another in a horizontal direction parallel to the + / - X axis of the coordinate axes depicted in the figures, and at least the build area 120 and the supply platform 130 are positioned therebetween. In embodiments, the build area 120 is positioned between the cleaning station 108 and the supply platform 130 along the working axis 116 of the system 100.

[0146] Still referring to FIG. 1Bposition 151, the print assembly 150 is positioned or "parked" at the home position 151 prior to and after depositing the adhesive material 50 on a layer of build material 40 positioned on the build area 120. The cleaning station 108 can include one or more cleaning sections to facilitate cleaning of the print assembly 150, and in particular, the plurality of print heads 156 of the print assembly 150, between deposition operations. The cleaning sections can include, for example and without limitation, a soak station containing a cleaning solution for dissolving excess adhesive material 50 from the plurality of print heads 156, a wiping station for removing excess adhesive material 50 from the plurality of print heads 156, a blast station for clearing the plurality of print heads 156 of adhesive material 50 and / or cleaning solution, and a park station for maintaining moisture in the plurality of ejection nozzles 158 of the plurality of print heads 156. The print assembly 150 can be transitioned between the cleaning sections by the first actuator assembly 102. In some embodiments, the apparatus 100 can include a blast test area positioned adjacent to one end of the working axis 116 of the apparatus 100 near the cleaning station 108 and / or the home position 151. Although not shown, it will be appreciated that the blast test area of the apparatus 100 can be configured to facilitate material deposition by the print assembly 150 prior to performing deposition along the build area 120.

[0147] The build area 120 is coupled to a build platform actuator 122 to facilitate raising and lowering the build area 120 in a vertical direction (i.e., a direction parallel to the + / - Z direction of the coordinate axes depicted in the figures) relative to the working axis 116 of the apparatus 100. The build platform actuator 122 can be, for example and without limitation, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, or any other actuator suitable for imparting linear motion to the build area 120 in the vertical direction. Suitable actuators can include, but are not limited to, a worm drive actuator, a ball screw actuator, a pneumatic piston, a hydraulic piston, an electromechanical linear actuator, and the like. The build area 120 and the build platform actuator 122 are positioned in a build reservoir 124, which is positioned below (i.e., in the -Z direction of the coordinate axes depicted in the figures) the working axis 116 of the apparatus 100. During operation of the apparatus 100, after each layer of adhesive material 50 is deposited on the build material 40 positioned on the build area 120, the build area 120 is retracted into the build reservoir 124 by action of the build platform actuator 122.

[0148] Still referring to FIG. 1BThe supply platform 130 is coupled to a supply platform actuator 132 to facilitate raising and lowering the supply platform 130 in a vertical direction (i.e., a direction parallel to the + / - Z direction of the coordinate axes depicted in the figures) relative to the working axis 116 of the apparatus 100. The supply platform actuator 132 can be, for example and without limitation, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, or any other actuator suitable for imparting linear motion to the supply platform 130 in the vertical direction. Suitable actuators can include, but are not limited to, a worm drive actuator, a ball screw actuator, a pneumatic piston, a hydraulic piston, an electromechanical linear actuator, and the like. The supply platform 130 and the supply platform actuator 132 are positioned in a supply reservoir 134, which is positioned below (i.e., in the -Z direction of the coordinate axes depicted in the figures) the working axis 116 of the apparatus 100. During operation of the apparatus 100, after a layer of build material 40 is distributed from the supply platform 130 to the build area 120, the supply platform 130 is raised relative to the supply reservoir 134 toward the working axis 116 of the apparatus 100 by action of the supply platform actuator 132, as will be described in further detail herein. It will be appreciated, however, that in other embodiments, the apparatus 100 does not include a supply platform 130, such as in embodiments in which build material is supplied to the build area 120 using, for example and without limitation, a build material hopper (see, e.g., FIG. 1A). FIG. 1C ) to the build area 120.

[0149] The print assembly 150 includes, among other elements, a support carriage 152, a print head 154, and a plurality of print heads 156. The support carriage 152 is movably coupled to the rails 104 and the first actuator assembly 102 of the apparatus 100 while the print head 154 is positioned along an opposite end of the support carriage 152 and movably coupled thereto via the second actuator assembly 103, which is configured to operably index the print head along a latitudinal axis. As described in greater detail herein, the print head 154 of the print assembly 150 can include two or more rows of the plurality of print heads 156, and in some embodiments, at least one row of the print heads is movable relative to the other row of the plurality of print heads 156. This allows the material deposition steps of the fabrication process to be performed with enhanced jetting reliability and jetting resolution by varying the relative position of at least one row of the movable print heads 156.

[0150] In some embodiments, however, the print assembly 150 includes a plurality of print heads 156, which can optionally include a plurality of jetting nozzles 158. The plurality of jetting nozzles 158 are spaced apart from one another in a direction transverse to the longitudinal axis, with a distance from a first jetting nozzle of the plurality of jetting nozzles to a second jetting nozzle positioned adjacent to the first jetting nozzle defining a jetting pitch, as described in greater detail herein.

[0151] Still referring toFIG. 1B The manufacturing apparatus 100 can further include a control system 10 communicatively coupled to the first actuator assembly 102, the second actuator assembly 103 (collectively referred to herein as print head position control assemblies), the re-coat assembly 140, and / or the print assembly 150. As described in greater detail herein, in some embodiments, in particular, the control system 10 can be coupled to one or more actuators (e.g., 160, FIG. 4 ) of the print assembly 150. In the present example, the control system 10 is coupled to the apparatus 100 via a communication conduit 12, however, it should be appreciated that in other embodiments, the control system 10 can be communicatively coupled to the apparatus 100 via various other means or systems, for example, through a wireless connection. The control system 10 (which can also be referred to as an electronic control unit) includes a processor and a non-transitory memory including computer readable executable instructions stored thereon. Any action of the apparatus 100, including those described herein, can be performed by the computer readable executable instructions stored in the non-transitory memory of the control system 10, as executed by the processor of the control system 10, causing the apparatus 100 to act. For example, one or more actuators (e.g., mechanical actuators, electromechanical actuators, pneumatic actuators, hydraulic actuators, worm drive actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, electromechanical linear actuators, etc.) of the first actuator assembly 102 can be actuated by the computer readable executable instructions stored in the non-transitory memory of the control system 10, as executed by the processor of the control system 10, to cause the print assembly 150 and / or the re-coat assembly 140 to move in the manner described herein. Moreover, as described in greater detail below, the computer readable executable instructions stored in the non-transitory memory can cause the control system 10, when executed by the processor, to perform various processes for moving the print assembly 150, actuating one or more actuators 160 of the print assembly 150 to move the rows of print heads 156, depositing material onto the build material 40 (e.g., powder or other material) in the build area 120, etc.

[0152] In some embodiments, the control system 10 can be further communicatively coupled to a computing device 15, optionally via the network 16, or directly via a communication link, such as wired or wireless. The computing device 15 can include a display 15a, a processing unit 15b (e.g., having at least a processor and memory), and an input device 15c, each of which can be communicatively coupled together and / or to the network 16. The computing device 15 can be configured to utilize the apparatus 100 to perform processes such as generating executable instructions for building a part. The processes can implement CAD or other related three-dimensional drafting and rendering systems, as well as slicing engines, among others. The slicing engine can be logically configured to receive a model or drawing of a part for building and process the model or drawing into build instructions to be performed by the apparatus 100 to build the part, the build instructions defining a plurality of motion control operations, powder layer placement, a deposition pattern for a binding agent, among others. The slicing engine can determine a number of powder layers that the build should include and locations within the layers of powder at which the binding agent should be dispensed. The deposition pattern for the binding agent can further include defining an amount (volume) of the binding agent to be dispensed at the particular locations within a layer of powder.

[0153] In some embodiments, the network 16 is a personal area network employing Bluetooth technology to communicatively couple the control system 10. In other embodiments, the network 16 can include one or more computer networks (e.g., personal, local, or wide area networks), cellular networks, satellite networks, and / or global positioning systems, and combinations thereof. As such, the control system 10 and / or the apparatus 100 can be communicatively coupled to the network 16 via a wire, via a wide area network, via a local area network, via a personal area network, via a cellular network, via a satellite network, and the like. Suitable local area networks can include wired Ethernet and / or wireless technologies, such as, for example, Wi-Fi. Suitable personal area networks can include wireless technologies such as, for example, IrDA, Bluetooth, Wireless USB, Z-Wave, ZigBee, and / or other near field communication protocols. Similarly, suitable personal area networks can include wired computer buses such as USB and FireWire. Suitable cellular networks include, but are not limited to, technologies such as LTE, WiMAX, UMTS, CDMA, and GSM.

[0154] The apparatus 100 further includes one or more fluid reservoirs fluidically coupled to the print assembly 150 via one or more conduit lines. In some embodiments, the print assembly 150 can also include one or more local fluid manifolds for locally storing fluid. In particular, the one or more fluid reservoirs can be fluidically coupled to a plurality of print heads 156 disposed within the print head 154 of the print assembly 150. In this example, a plurality of ejection nozzles 158 (see FIG. 2) of each of the plurality of print heads 156 are in fluid communication with the material stored within the one or more fluid reservoirs. FIGS. 2-2 0)FIG. 1B One or more fluid reservoirs are depicted as including a first fluid reservoir 110 containing a first material 114 stored therein and a second fluid reservoir 112 containing a second material 115 stored therein, where the first material 114 is different than the second material 115. The first fluid reservoir 110 is in fluid communication with the plurality of print heads 156 in the print head 154 via a first conduit 111, and the second fluid reservoir 112 is in fluid communication with the plurality of print heads 156 in the print head 154 via a second conduit 113. In some embodiments, the first fluid reservoir 110 and the second fluid reservoir 112 can contain the same material. In some embodiments, the plurality of print heads 156 of the print head 154 can be coupled to a single fluid reservoir containing the same material, such that the plurality of print heads 156 are configured to deposit the same material.

[0155] As will be described in greater detail herein, in some embodiments, the first fluid reservoir 110 is coupled to a different subset (i.e., first subset) of the plurality of print heads 156 than the second fluid reservoir 112 (i.e., second subset), such that the plurality of print heads 156 collectively receive and dispense each of the first material 114 and the second material 115, but each of the plurality of print heads 156 of the print assembly 150 receives and dispenses one of the first material 114 or the second material 115. In other embodiments, the first conduit line 111 and the second conduit line 113 can be coupled to one another at a coupling mechanism, such as, for example, a manifold, a valve, or the like. In this example, the fluid reservoirs 110, 112 are in fluid communication with the coupling mechanism via the conduit lines 111, 113, where the coupling mechanism includes a third conduit line coupled thereto and extending to the print head 154. The coupling mechanism can be configured to selectively switch fluid communication between the fluid reservoirs 110, 112 and the print head 154, such that the plurality of print heads 156 receive one of the first material 114 or the second material 115 in response to actuation of the coupling mechanism. It will be appreciated that the coupling mechanism can be further configured to facilitate simultaneous fluid communication of the first fluid reservoir 110 and the second fluid reservoir 112 with the print head 154, such that the plurality of print heads 156 simultaneously receive both materials 114, 115.

[0156] Reference is made to FIG. 1C In some embodiments, the manufacturing apparatus 100 includes a cleaning station 108 and a build area 120, as described herein with reference to FIG. 1B However, in FIG. 1CIn the depicted embodiment, the manufacturing apparatus 100 does not include a supply reservoir and / or platform. Instead, the apparatus 100 includes a build material hopper 170 to supply build material 40 to the build area 120. In this embodiment, the build material hopper 170 is coupled to the recoat assembly cross-car actuator 148 such that the build material hopper 170 traverses along with the recoat assembly 140 along the recoat axis of motion 146. In FIG. 1C In the depicted embodiment, the build material hopper 170 is coupled to the support carriage 144 of the recoat assembly 140, for example, with a carriage 172. However, it should be appreciated that the build material hopper 170 can be coupled directly to the support carriage 144 of the recoat assembly 140 without an intermediate carriage. Alternatively, the build material hopper 170 can be coupled to the recoat assembly 140 either directly or with an intermediate carriage.

[0157] The build material hopper 170 can include an electrically actuated valve (not depicted) to release build material 40 onto the build area 120 as the build material hopper 170 traverses over the build area 120. In embodiments, the valve can be communicatively coupled to the control system 10 (i.e., electronic control unit) that executes computer readable executable instructions to open and close the valve based on the position of the build material hopper 170 relative to the build area 120. The build material 40 released onto the build area 120 is then distributed over the build area 120 with the recoat assembly 140 as the recoat assembly 140 traverses over the build area 120.

[0158] Referring to FIG. 1D The object multi-layer build material 40AA-40DD can be positioned on top of one another in sequence as deposited on the build area 120. In FIG. 1D In the example provided, successive multi-layer adhesives 50AA-50CC are positioned on the multi-layer build material 40AA-40DD. By curing the multi-layer adhesives 50AA-50CC, a finished product can be formed.

[0159] Referring now to FIGS. 2-9 The print head 154 of the print assembly 150 is schematically depicted with a plurality of print heads 156 positioned therein. In particular, FIGS. 2-9 The bottom end 159 of the print head 154 is schematically depicted, by which the plurality of print heads 156 disposed therein are illustrated. It should be appreciated that the plurality of print heads 156 are exposed from within the print head 154 of the print assembly 150 along the bottom end 159 of the print head 154. Referring to FIGS. 2-9 As briefly noted above, each of the plurality of print heads 156 disposed within the print head 154 includes a plurality of ejection nozzles 158 for depositing adhesive material 50, first material 114, second material 115, and / or other materials therefrom.

[0160] In some embodiments described herein, the printhead 154 of the printing assembly 150 includes a number of rows of printheads 156, specifically, at least a first printhead row 155 of printheads 156 and a second printhead row 157 of printheads 156. As will be described in greater detail herein, in other embodiments, the printhead 154 of the printing assembly 150 can include additional or fewer rows of printheads 156 (see FIGS. 12-16 ). For example, in some embodiments, the printhead 154 of the printing assembly 150 can include a single row of printheads 156. While the first printhead row 155 and the second printhead row 157 of printheads 154 are shown herein as including three printheads 156 each, it should be understood that this description is for illustrative purposes only and that such depiction is for illustrative purposes and that, in embodiments, the first printhead row 155 and / or the second printhead row 157 include more or fewer printheads 156.

[0161] It should further be understood that each of the plurality of printheads 156 includes a plurality of ejection nozzles 158. While the present example depicts each printhead 156 as having four ejection nozzles 158 therein, it should be understood that this is for illustrative purposes only and that each of the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 includes a plurality of ejection nozzles 158, in many instances, many more than four ejection nozzles. As such, embodiments in which each of the plurality of printheads 156 disposed within the printhead 154 includes more or fewer ejection nozzles 158 are contemplated and are possible. By way of example only, each printhead 156 can include a plurality of ejection nozzles 158 from about 5 nozzles to about 50 nozzles, from about 50 nozzles to about 100 nozzles, from about 100 nozzles to about 500 nozzles, from about 500 nozzles to about 1000 nozzles, from about 1000 nozzles to about 2000 nozzles, from about 2000 nozzles to about 3000 nozzles, from about 3000 nozzles to about 4000 nozzles, from about 4000 nozzles to about 5000 nozzles, from about 5000 nozzles to about 6000 nozzles, wherein each ejection nozzle 158 is spaced apart from one another. The nozzles can be spaced apart from one another by 1 / 10 of an inch to about 1 / 1200 of an inch, or any value therebetween, such as, for example, 1 / 100 of an inch, 1 / 200 of an inch, 1 / 300 of an inch, 1 / 400 of an inch, 1 / 500 of an inch, 1 / 600 of an inch, 1 / 700 of an inch, 1 / 800 of an inch, 1 / 900 of an inch, 1 / 1000 of an inch, 1 / 1100 of an inch, or 1 / 1200 of an inch. The distance "d" from a first ejection port in the plurality of ejection ports to a second ejection port positioned adjacent the first ejection port corresponds to the ejection pitch (d) FIG. 21A ).

[0162] With more particular reference to FIG. 2 In particular, the print head rows 155, 157 extend along a length "L" of the print head 154 such that the print head rows 155, 157 have a similar length as the length "L" of the print head 154. In the present example, the print head rows 155, 157 include an equal length relative to one another, however, it should be appreciated that in other embodiments, the print head rows 155, 157 can have varying lengths relative to one another and in comparison to the lengths shown and described herein. The print head rows 155, 157 are sized and shaped to respectively slidably receive at least one print head 156 therein, in particular, a plurality of print heads 156. The print head rows 155, 157 are positioned parallel to one another along the bottom end 159 of the print head 154 and are aligned in a collinear arrangement relative to one another.

[0163] Referring now to FIG. 3 In particular, the print head rows 155, 157 extend along a length "L" of the print head 154 such that the print head rows 155, 157 have a similar length as the length "L" of the print head 154. In the present example, the print head rows 155, 157 include an equal length relative to one another, however, it should be appreciated that in other embodiments, the print head rows 155, 157 can have varying lengths relative to one another and in comparison to the lengths shown and described herein. The print head rows 155, 157 are sized and shaped to respectively slidably receive at least one print head 156 therein, in particular, a plurality of print heads 156. The print head rows 155, 157 are positioned parallel to one another along the bottom end 159 of the print head 154 and are aligned in a collinear arrangement relative to one another.

[0164] As briefly described above, the plurality of print heads 156 can be configured to be slidably translatable within the print head rows 155, 157, respectively, in a cross direction relative to the working axis 116 of the device 100 (i.e., in the + / - Y direction shown in the figures). In the present example, the print head 154 of the print assembly 150 includes a pair of print head rows 155, 157 defined by three print heads 156 in each row, respectively. It should be appreciated that the print head 154 of the print assembly 150 is configured to be modular such that in other embodiments, additional print head rows and / or print heads 156 can be included without departing from the scope of the present disclosure. Each of the print heads 156 includes a coupling feature 149 attached thereto. Although FIG. 3 Although not shown in FIG. 1, the coupling features 149 of each of the print heads 156 in the print head rows 155, 157 are further attached to an actuator 160 (see FIG. 2) at an opposite end of the print heads 156.FIGS. 4-2 0). As will be described in greater detail herein, the actuators 160 are configured to move the plurality of printheads 156 of the first printhead row 155 and / or the second printhead row 157 upon actuation of the actuators 160, which can be caused by execution of computer-readable executable instructions stored in the non-transitory memory of the control system 10 by the processor of the control system 10. In some embodiments, such as with reference to the embodiments depicted and described herein, the print assembly 150 can be capable of being indexed along the latitudinal axis via the second actuator assembly 103 FIGS. 21A-21B FIG. 21A ) in addition to the independent movement of the plurality of printheads 156 described with reference to FIGS. 4-2 0, or the plurality of printheads 156 can be fixed to a location within the print assembly 150 (i.e., without the actuators 160).

[0165] With specific reference to FIG. 4 , the first printhead row 155 of the plurality of printheads 156 is positioned relative to the second printhead row 157 of the plurality of printheads 156 such that the first printhead row 155 is spaced apart from the second printhead row 157 along the working axis 116 of the apparatus 100 (i.e., in the + / - X direction of the coordinate axis depicted in the figures). Each of the plurality of printheads 156 in the first printhead row 155 is in turn spaced apart from one another in a direction transverse to the working axis 116 of the apparatus 100 (in the + / - Y direction of the coordinate axis depicted in the figures). Similarly, each of the plurality of printheads 156 in the second printhead row 157 is in turn spaced apart from one another in a direction transverse to the working axis 116 of the apparatus 100 (in the + / - Y direction of the coordinate axis depicted in the figures).

[0166] ​In the default position, the plurality of printheads 156 in the first printhead row 155 can be positioned such that they at least partially overlap the plurality of printheads 156 in the second printhead row 157 in the + / -X direction of the coordinate axis (i.e., along the working axis 116). It will be appreciated that in some embodiments, the plurality of printheads 156 in the first printhead row 155 are laterally offset (in the + / -Y direction of the coordinate axis depicted in the figures) from the plurality of printheads 156 in the second printhead row 157 by at least about one-half the width and / or diameter of the ejection nozzles 158 when the printhead rows 155, 157 are in the default position. As will be described in greater detail herein, the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 can be laterally offset relative to one another in a direction transverse to the working axis 116 (the + / -Y direction of the coordinate axis depicted in the figures) such that at least one printhead 156 in the first printhead row 155 and / or the second printhead row 157 is displaced in the + / -Y direction of the coordinate axis depicted in the figures relative to another printhead 156 in the adjacent row when the printhead 154 is in the actuated position. It will be appreciated, however, that in some embodiments, at least one printhead 156 in the first printhead row 155 and / or the second printhead row 157 can continue to overlap at least one opposing printhead 156 in the adjacent row when the printhead 154 is in the actuated position (see FIGS. 5-9 ) It will be further appreciated that the default position of the plurality of printheads 156 in either printhead row 155, 157 can be different from that depicted and described herein such that the default position of each printhead row 156 can be distinguished from the default position of the adjacent printhead row 156. As will be described in greater detail herein, moving one or more of the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 provides print redundancy across a plurality of pixels along the build area 120, whereby a final deposited geometry is formed in which each of the plurality of pixels receives a material deposit thereon from more than one of the plurality of ejection nozzles 158.

[0167] Still referring to FIG. 4The printheads 154 of the print assembly 150 further include at least one actuator 160 coupled to at least one of the plurality of printheads 156 positioned within the first printhead row 155 of the print head 156. The actuator 160 is configured to move at least one of the plurality of printheads 156 in the first printhead row 155 (e.g., a first printhead 156') in response to actuation of the actuator 160 (e.g., a first actuator 160'). The first printhead 156' is moved relative to the support carriage 152 of the print assembly 150. In particular, the first actuator 160' translates the first printhead 156' in a direction transverse to the working axis 116 (in the + / -Y direction of the coordinate axis depicted in the figures) such that the first printhead 156' is moved relative to the support carriage 152 (see FIG. 4 ) in a direction transverse to the working axis (in the + / -Y direction of the coordinate axis depicted in the figures). In some embodiments, as will be described in greater detail herein, the relative distance between the first printhead 156' and an adjacent printhead 156 in the second printhead row 157 can also be adjusted in response to the translation of the first printhead 156' within the first printhead row 155. FIG. 1B

[0168] In the embodiments described herein, the actuator 160 of the at least one printhead 156 can be, for example and without limitation, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, a motorized actuator, a non-motorized actuator, or any other actuator suitable for providing at least linear motion. Suitable actuators can include, but are not limited to, linear stages, worm drive actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, electromechanical linear actuators, and the like. By way of example, the actuator 160 can comprise a linear stage actuator, such as a 150 MM linear motor stage with at least 4 um accuracy.

[0169] Still referring to FIG. 4 In some embodiments, the printheads 154 of the print assembly 150 include a plurality of actuators 160, and in particular, at least one actuator 160 for each of the plurality of printheads 156 in the first printhead row 155. In this example, as will be described in greater detail herein, each of the plurality of printheads 156 in the first printhead row 155 can be moved in a direction transverse to the working axis (in the + / -Y direction of the coordinate axis depicted in the figures) relative to one another and relative to the support carriage 152 (see FIG. 1B ​) move. In other words, each of the plurality of printheads 156 in the first printhead row 155 is capable of moving independently of one another such that adjacent printheads 156 in the first printhead row 155 can translate in opposite directions and / or at varying angles (i.e., distances) relative to one another along the + / - Y direction of the coordinate axis.

[0170] In some embodiments, the printhead 154 can include at least one spacer positioned between adjacent printheads 156 in the first printhead row 155 such that the spacing between adjacent and independently movable printheads 156 is uniformly increased and / or decreased relative to one another. In other embodiments, a limited number of printheads 156 within the first printhead row 155 can include one of the plurality of actuators 160 coupled thereto (e.g., every other printhead 156 of the first printhead row 155; outer printheads 156 of the first printhead row; inner printheads 156 of the first printhead row; etc.) such that not every printhead 156 in the first printhead row 155 is capable of independent movement.

[0171] In some embodiments, more than one of the plurality of printheads 156 in the first printhead row 155 can be coupled to a single actuator 160 such that the coupled printheads 156 can move in unison in a direction transverse to the working axis 116 (the + / - Y direction of the coordinate axis shown in the figures). In some embodiments, all of the printheads 156 in a single row can be coupled to a single actuator 160, e.g., all of the plurality of printheads 156 in the first printhead row 155 can be coupled to a single actuator 160 such that all of the printheads 156 in the first printhead row 155 move in unison in a direction transverse to the working axis 116 (the + / - Y direction of the coordinate axis shown in the figures). Alternatively, all of the printheads 156 in several rows can be coupled to a single actuator 160, e.g., all of the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 can be coupled to a single actuator 160 such that all of the printheads 156 in the printhead 154 move in unison in a direction transverse to the working axis 116 (the + / - Y direction of the coordinate axis shown in the figures).

[0172] Still referring to FIG. 4In some embodiments, when one or more of the print heads 156 in the single row 155 does not currently require use for performing an additive manufacturing process, one or more of the print heads 156 can be capped to protect the plurality of ejection nozzles 158 of the respective print head 156 from the printing process. In particular, a print head cap 166 can be positioned along a face plate of one or more of the print heads 156 such that the plurality of ejection nozzles 158 are effectively covered with and / or receive the print head cap 166 therein. In this example, the plurality of ejection nozzles 158 in the capped print head 156 can be shielded from dust during use of the printing assembly 150. When necessary, the capped print head 156 can be uncapped, thereby exposing the plurality of ejection nozzles 158 therein, for performing an additive manufacturing process.

[0173] In other embodiments, the print head 154 can include at least one actuator 160 coupled to the plurality of print heads 156 defining the first print head row 155 for moving the plurality of print heads 156 and another actuator 160 coupled to the plurality of print heads 156 defining the first print head row 155 for varying a distance (e.g., pitch) between the plurality of print heads 156 in the first print head row 155. In this example, even though the plurality of print heads 156 in the first print head row 155 are moved in unison with one another in response to actuation of the single actuator 160, the pitch between each of the plurality of print heads 156 can be selectively controlled (e.g., increased or decreased) by the other actuator 160 coupled to the print heads 156 in the first print head row 155. In this example, the plurality of print heads 156 in the second print head row 157 do not include an actuator coupled thereto, such that the second print head row 157 of the plurality of print heads 156 are fixed relative to one another, relative to the support bracket 152 (see FIG. 1B ) and relative to the plurality of print heads 156 in the first print head row 155. However, as described below, one or more of the print heads 156 in the second print head row 157 can also be moved relative to the support bracket 152 in the + / - Y direction of the coordinate axis.

[0174] Reference is now made to FIG. 5 In some embodiments, the print head 154 of the printing assembly 150 includes at least one actuator 160 coupled to at least one of the plurality of print heads 156 positioned within the second print head row 157. The actuator 160 is configured to move at least one print head 156 (e.g., a second print head 156”) of the plurality of print heads 156 in the second print head row 157 in response to actuation of the actuator 160 (e.g., a second actuator 160”). The second print head 156” is moveable relative to the support bracket 152 (seeFIG. 1B ) moves. In particular, the second actuator 160” translates the second printhead 156” in a direction transverse to the working axis 116 (i.e., in the + / -Y direction of the coordinate axis depicted in the figures) such that the second printhead 156” moves relative to the support carriage 152 (see FIG. 4 ) in a direction transverse to the working axis 116 (i.e., in the + / -Y direction of the coordinate axis depicted in the figures). In some embodiments, as will be described in greater detail herein, the relative distance between the second printhead 156” and an adjacent printhead 156 in the first printhead row 155 can also be adjusted in response to the translation of the second printhead 156” within the second printhead row 157. FIG. 1B

[0175] In other embodiments, the printhead 154 of the printing assembly 150 includes a plurality of actuators 160, and in particular, at least one actuator 160 for each of the plurality of printheads 156 in the second printhead row 157. In this instance, as will be described in greater detail herein, each of the plurality of printheads 156 in the second printhead row 157 can move relative to one another in response to actuation of the respective actuator 160 coupled thereto. In other words, each of the plurality of printheads 156 in the second printhead row 157 is capable of moving independently of one another such that adjacent printheads 156 in the second printhead row 157 can translate relative to one another in opposite directions and / or at varying angles (i.e., distances) along the + / -Y direction of the coordinate axis. As a result of the one or more printheads 156 in each of the printhead rows 155, 157 being coupled to at least one actuator 160, the printhead 154 of the printing assembly 150 can produce a variable print width that is configured to expand or contract as needed.

[0176] Referring now to FIG. 6 In other embodiments, the printhead 154 of the printing assembly 150 includes a single actuator 160 coupled to the plurality of printheads 156 within the first printhead row 155. The actuator 160 is configured to move the plurality of printheads 156 in the first printhead row 155 in unison relative to the support carriage 152 (see FIG. 1B ) of the printing assembly 150 in a direction transverse to the working axis 116 of the device 100 (i.e., in the + / -Y direction of the coordinate axis depicted in the figures). In other words, actuation of the actuator 160 provides for the plurality of printheads 156 in the first printhead row 155 to translate in unison relative to the plurality of printheads 156 in the second printhead row 157. In this instance, the relative distance (e.g., pitch) between each of the plurality of printheads 156 in the first printhead row 155 is maintained such that the offset between adjacent printheads 156 within the first printhead row 155 does not change as the first printhead row 155 of printheads 156 translates.​

[0177] In this example, the plurality of printheads 156 in the second printhead row 157 do not include actuators coupled thereto, such that the second printhead row 157 of the plurality of printheads 156 is securely fixed relative to the plurality of printheads 156 in the first printhead row 155. In other embodiments, a single actuator 160 may be coupled to both the first printhead row 155 and the second printhead row 157, such that actuation of the actuator 160 provides both rows 155, 157 in a direction transverse to the working axis 116 of the device 100 (i.e., in the + / -Y direction of the coordinate axis depicted in the figure) relative to the support bracket 152 (see FIG. 1B Consistent translation.

[0178] refer to FIG. 7 In some embodiments, the print head 154 of the print assembly 150 includes a second actuator 160' coupled to a plurality of print heads 156 positioned within a second print head row 157 of the print head 156. The second actuator 160' is configured to move the plurality of print heads 156 in the second print head row 157 in response to actuation of the second actuator 160'. The plurality of print heads 156 in the second print head row 157 are positioned relative to a support bracket 152 of the print assembly 150 (see [link to documentation]). FIG. 1B The second actuator 160' translates multiple printheads 156 in the second printhead row 157 in a direction transverse to the working axis 116 (i.e., in the + / - Y direction of the coordinate axis depicted in the figure). In other words, actuation of the second actuator 160' provides synchronized translation of the multiple printheads 156 in the second printhead row 157 relative to the multiple printheads 156 in the first printhead row 155. The multiple printheads 156 in the first printhead row 155 move in sync with the multiple printheads 156 in the second printhead row 157. FIG. 7 The coordinate axis (in the +Y direction) is opposite to the direction ( FIG. 7 The coordinate axis is translated in the -Y direction. It should be understood that the plurality of printheads 156 in the first printhead row 155 can exchange positions with the plurality of printheads 156 in the second printhead row 157. In this example, the relative distance between each of the plurality of printheads 156 in the second printhead row 157 is maintained such that when the printheads 156 are translated in the second printhead row 157, the offset between adjacent printheads 156 within the second printhead row 157 does not change.

[0179] In some embodiments, the actuators 160 of the print head 154 are configured to move one or more of the plurality of print heads 156 in the first print head row 155 and / or the second print head row 157 in various other directions (i.e., directions other than the + / -Y directions of the coordinate axes depicted in the figures) than those depicted and described above. For example, the actuators 160 of the print head 154 can be configured to move one or more of the plurality of print heads 156 in the first print head row 155 and / or the second print head row 157 in a direction parallel to the working axis 116 of the apparatus 100 (i.e., in the + / -X directions of the coordinate axes depicted in the figures), in another direction transverse to the working axis 116 (i.e., in the + / -Z directions of the coordinate axes depicted in the figures), and so forth.

[0180] With specific reference now to FIG. 8 In some embodiments, the print head 154 of the printing assembly 150 includes a plurality of actuators 160, and in particular, each of the plurality of print heads 156 in the first print head row 155 is respectively coupled to at least one actuator 160. Further, the plurality of print heads 156 in the second print head row 157 are collectively coupled to a single actuator 160. In this example, the plurality of actuators 160 coupled to the plurality of print heads 156 in the first print head row 155 are configured to selectively and individually move each print head 156 in a direction parallel to the working axis 116 of the apparatus 100 (i.e., in the + / -X directions of the coordinate axes depicted in the figures).

[0181] In this example, each of the plurality of print heads 156 in the first print head row 155 is independently movable from one another such that adjacent print heads 156 in the first print head row 155 can translate relative to one another and the support carriage 152 (see FIG. 1B ) in opposite directions and / or at varying angles (i.e., distances) along the + / -X directions of the coordinate axes. Although not shown, it should be appreciated that in other embodiments, the plurality of print heads 156 in the second print head row 157 can be coupled to a plurality of actuators 160 instead of the single actuator 160 shown and depicted herein such that the plurality of print heads 156 in the second print head row 157 are each movable in synchronization with the plurality of print heads 156 in the first print head row 155. In other embodiments in which the print head 154 of the printing assembly 150 includes a plurality of actuators 160 coupled to the plurality of print heads 156 in the first print head row 155 and the plurality of print heads 156 in the second print head row 157 are collectively coupled to a single actuator 160, the plurality of actuators 160 can be configured to selectively and individually rotate each print head 156 in the first print head row 155.

[0182] With specific reference now to FIG. 9coupled to the plurality of printheads 156 in the first printhead row 155 are configured to rotate and / or pivot each of the printheads 156 about an axis of rotation that is transverse to the working axis 116 of the apparatus 100 (i.e., an axis of rotation that is parallel to the + / - Z direction of the coordinate axis depicted in the figure) independently of adjacent printheads 156 in the first printhead row 155. In other words, each of the plurality of printheads 156 in the first printhead row 155 is rotatable relative to one another and the support bracket 152 (see FIG. 1B ) such that adjacent printheads 156 in the first printhead row 155 can be rotated in opposite directions and / or at varying angles relative to one another about the axis of rotation. Although not shown, it should be appreciated that in other embodiments, similarly, the plurality of printheads 156 in the second printhead row 157 can be coupled to a plurality of actuators 160, rather than the single actuator 160 shown and depicted herein, such that the plurality of printheads 156 in the second printhead row 157 are each rotatable in synchronization with the plurality of printheads 156 in the first printhead row 155.

[0183] Reference is now made to FIGS. 10-11 schematically depicting the print head 154 of the print assembly 150 in which at least one of the plurality of printheads 156 in the first printhead row 155 (i.e., a first printhead 156’) and at least one of the plurality of printheads 156 in the second printhead row 157 (i.e., a second printhead 156”) are disposed.

[0184] With particular reference to FIG. 10 when in the default position, the first printhead row 155 and the second printhead row 157 of printheads 156 are positioned at a predetermined elevation (i.e., height) within the print head 154 relative to the bottom end 159 of the print head 154. In some embodiments, the print head 154 of the print assembly 150 includes a plurality of actuators 160 and, in particular, each of the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 is coupled to at least one actuator 160, respectively. In this example, the plurality of actuators 160 coupled to the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 are configured to selectively and independently move each of the printheads 156 in a direction transverse to the working axis 116 of the apparatus 100 (i.e., in the + / - Z direction of the coordinate axis depicted in the figure).

[0185] Accordingly, each of the plurality of print heads 156 in the first print head row 155 and / or the second print head row 157 can be moved independently of one another such that adjacent print heads 156 in the first print head row 155 and / or the second print head row 157 can be translated in opposite directions and / or at varying angles (i.e., distances) relative to one another along the + / - Z direction of the coordinate axis. In other words, the plurality of actuators 160 are configured to adjust the height of the plurality of print heads 156 in the first print head row 155 and / or the second print head row 157 relative to one another, relative to the bottom end 159 of the print head 154, and the height of the build area 120 on which the print assembly 150 is positioned when depositing the adhesive material 50, the first material 114, the second material 115, and the like. In other embodiments, the height of the plurality of print heads 156 in the first print head row 155 and / or the second print head row 157 can be adjusted in instances where the plurality of print heads 156 are to be inactive during the current printing cycle. In this instance, the first print head row 155 or the second print head row 157 can be moved in the +Z direction of the coordinate axis to vertically offset the inactive plurality of print heads 156 positioned therein.

[0186] Referring now to FIG. 1, a schematic view of a print assembly 150 is shown in accordance with an embodiment of the present disclosure. The print assembly 150 includes a print head 154, a first print head row 155, and a second print head row 157. The print head 154 is configured to deposit an adhesive material 50, a first material 114, a second material 115, and the like onto a build area 120. The first print head row 155 and the second print head row 157 are positioned on the print head 154 and are configured to deposit the adhesive material 50, the first material 114, the second material 115, and the like onto the build area 120. The first print head row 155 and the second print head row 157 are positioned on the print head 154 such that the first print head row 155 and the second print head row 157 are positioned on opposite sides of the print head 154. FIG. 11 In response to actuation of the actuator 160 coupled thereto, the first print head 156 in the first print head row 155 is moved in the -Z direction of the coordinate axis toward the bottom end 159 of the print head 154. In response to actuation of the second actuator 160' coupled thereto, the second print head 156" in the second print head row 157 is moved in the +Z direction of the coordinate axis away from the bottom end 159 of the print head 154. Although the first print head 156 and the second print head 156' are depicted as being translated in opposite directions relative to one another along the + / - Z direction of the coordinate axis, it should be appreciated that in other embodiments, the first print head 156 and the second print head 156' can be swapped in position and / or moved in similar directions and / or at similar distances.

[0187] While not shown, it should be further understood that in other embodiments, the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 can be collectively coupled to a single actuator 160, respectively, rather than the plurality of actuators 160 shown and depicted herein. In this example, the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 can be moved in unison synchronously relative to adjacent printheads 156 within the same printhead row 155, 157. However, the plurality of printheads 156 in the first printhead row 155 remain capable of moving independently relative to the plurality of printheads 156 in the second printhead row 157. In other embodiments, the plurality of printheads 156 defining the first printhead row 155 and the second printhead row 157 can be collectively coupled to a single actuator 160 such that the printheads 156 of both rows 155, 157 move in unison relative to the support carriage 152 (see FIG. 1B ) one another. It should be understood that other orientations, configurations, and orientations of movement of the plurality of printheads 156 relative to one another and / or the first printhead row 155 relative to the second printhead row 157 can be incorporated in connection with the printing assembly 150 herein without departing from the scope of the present disclosure, and vice versa.

[0188] FIGS. 12-16 Another embodiment of a three-row printing assembly including several rows of printheads 156 arranged within a print head 254 is schematically depicted. It should be understood that the three-row printing assembly of the present example can be readily incorporated into the manufacturing apparatus 100 described above. It should be further understood that the three-row printing assembly functions in many respects substantially similar to the printing assembly 150 described above. As such, a version of the apparatus 100 equipped with the three-row printing assembly of the present example can be configured and operable similar to the printing assembly 150 described above, except as described below. Since the three-row printing assembly is substantially similar to the printing assembly 150, like reference numerals are used to identify like components. However, the three-row printing assembly differs from the printing assembly 150 in that the three-row printing assembly includes a print head 254 in which a third printhead row 256 of printheads 156 is arranged.

[0189] With specific reference now to FIG. 12, each of the plurality of printheads 156 in the third printhead row 256 is spaced apart from one another sequentially in a direction transverse to the working axis 116 of the device 100 (i.e., in the + / -Y direction of the coordinate axis depicted in the figure). The plurality of printheads 156 in the third printhead row 256 are disposed proximate to the second printhead row 157 and are distally spaced apart from the first printhead row 155 in a direction parallel to the working axis 116 of the device 100 (i.e., in the + / -X direction of the coordinate axis depicted in the figure). In this example, the second printhead row 157 is disposed between the first printhead row 155 and the third printhead row 256. Each of the plurality of printheads 156 in the third printhead row 256 includes a plurality of nozzles 158 positioned proximate to a bottom end 3259 of the print head 254, respectively.

[0190] Reference is now made to FIG. 13 In some embodiments, the print head 254 of the printing assembly includes a first actuator 160 coupled to the plurality of printheads 156 positioned within the first printhead row 155 of printheads 156, a second actuator 160' coupled to the plurality of printheads 156 positioned within the second printhead row 157 of printheads 156, and a third actuator 160" coupled to the plurality of printheads 156 positioned within the third printhead row 256 of printheads 156. In this example, the third actuator 160" is configured to move the plurality of printheads 156 in the third printhead row 256 in response to actuation of the third actuator 160". The plurality of printheads 156 in the third printhead row 256 are moved relative to the support carriage 152 (see FIG. 1B ) of the printing assembly. In particular, the third actuator 160" translates the plurality of printheads 156 in the third printhead row 256 in a direction transverse to the working axis 116 (i.e., in the + / -Y direction of the coordinate axis depicted in the figure).

[0191] In this manner, actuation of the third actuator 160" provides for synchronous translation of the plurality of printheads 156 in the third printhead row 256 relative to the plurality of printheads 156 defining the first printhead row 155 and the second printhead row 157. In this example, the relative distance between each of the plurality of printheads 156 in the third printhead row 256 is maintained such that the offset (i.e., spacing) between adjacent printheads 156 defining the third printhead row 256 does not change as the third printhead row 256 of printheads 156 is translated. In this example, the plurality of printheads 156 in the first printhead row 155 and the plurality of printheads 156 in the third printhead row 256 are depicted as moving in the -Y direction of the coordinate axis, while the plurality of printheads 156 in the second printhead row 157 disposed therebetween are depicted as moving in the +Y direction of the coordinate axis.

[0192] It should be appreciated that the plurality of rows of printheads 156 can interchangeably swap positions and / or translate to various other lateral angles as compared to the angles shown and described herein. In some embodiments, the three rows of printheads 156 can be collectively coupled to a single actuator 160 such that the first, second, and third rows of printheads 155, 157, 256 of printheads 156 are configured to move in unison relative to the support carriage 152 (see FIG. 1B ) In other embodiments, the plurality of printheads 156 in the first 155 and / or second 157 rows of printheads can not include an actuator coupled thereto such that the first 155 and / or second 157 rows of printheads 156 are fixedly secured relative to the plurality of printheads 156 in the third row 256 of printheads.

[0193] Referring now to FIG. 14 In some embodiments, the printhead 254 of the printing assembly includes at least one actuator 160 coupled to at least one of the plurality of printheads 156 positioned within the first row 155 of printheads 156, at least one actuator 160 coupled to at least one of the plurality of printheads 156 positioned within the second row 157 of printheads 156, and at least one actuator 160 coupled to at least one of the plurality of printheads 156 positioned within the third row 256 of printheads 156. In this example, the actuator coupled to at least one printhead 156 (i.e., first printhead 156) in the first row 155 of printheads (i.e., first actuator 160) is configured to move the first printhead 156 within the first row 155 of printheads independently of the plurality of printheads 156 in the first row 155 of printheads and the plurality of printheads 156 in the second and third rows 157, 256 of printheads.

[0194] Further, the actuator coupled to at least one printhead 156 (i.e., second printhead 156') in the second row 157 of printheads (i.e., second actuator 160') is configured to move the second printhead 156' within the second row 157 of printheads independently of the plurality of printheads 156 in the second row 157 of printheads and the plurality of printheads 156 in the first and third rows 155, 256 of printheads. Similarly, the actuator coupled to at least one printhead 156 (i.e., third printhead 156") in the third row 256 of printheads (i.e., third actuator 160") is configured to move the third printhead 156" within the third row 256 of printheads independently of the plurality of printheads 156 in the third row 256 of printheads and the plurality of printheads 156 in the first and second rows 155, 157 of printheads.

[0195] Still referring to FIG. 14, the first printhead 156, the second printhead 156', and the third printhead 156" are moved relative to the support carriage 152 of the print assembly (see FIG. 1B In particular, the actuators 160, 160', 160" translate the printheads 156, 156', 156" in a direction transverse to the working axis 116 of the apparatus 100 (i.e., in the + / -Y direction of the coordinate axis depicted in the figures), such that the relative positions between the printheads 156, 156', 156" and the support carriage 152 in the + / -Y direction are changed. As will be described in greater detail herein, in some embodiments, the relative distances between the printheads 156, 156', 156" and adjacent printheads 156 in the other printhead row 155, 157, 256 can also be adjusted in response to the translation of the printheads 156, 156', 156" within the respective printhead row 155, 157, 256.

[0196] In the present example, the first printhead 156 in the first printhead row 155 and the third printhead 156" in the third printhead row 256 are depicted as moving in the -Y direction of the coordinate axis, while the second printhead 156' in the second printhead row 157 disposed therebetween is depicted as moving in the +Y direction of the coordinate axis. In other embodiments, the first printhead 156 in the first printhead row 155 and / or the second printhead 156' in the second printhead row 157, as well as other printheads 156 within the printhead rows 155, 157, can not each include an actuator coupled thereto, such that the first printhead row 155 and / or the second printhead row 157 of printheads 156 are at least fixedly secured relative to the third printhead 156" in the third printhead row 256.

[0197] Still referring to FIG. 14 In some embodiments, the printhead 254 of the print assembly includes a plurality of actuators 160, and in particular, at least one actuator 160 for each of the plurality of printheads 156 in the first printhead row 155, the second printhead row 157, and the third printhead row 256. In this example, as will be described in greater detail herein, each of the plurality of printheads 156 in the first printhead row 155, the second printhead row 157, and the third printhead row 256 can be moved relative to one another in response to actuation of the respective actuator 160 coupled thereto. In other words, each of the plurality of printheads 156 in the first printhead row 155, the second printhead row 157, and the third printhead row 256 can be moved independently of one another, such that adjacent printheads 156 can be moved relative to one another and the support carriage 152 (see FIG. 1B) in the opposite direction and / or at varying angles (i.e., distances). As described in greater detail herein, in other embodiments, the plurality of printheads 156 in the first printhead row 155, the second printhead row 157, and / or the third printhead row 256 can each not include an actuator coupled thereto, such that the printhead rows of printheads 156 are fixedly secured relative to one another and to the plurality of printheads 156 of the other rows.

[0198] Referring now to FIG. 15 In some embodiments, at least one of the rows of the plurality of printheads 156 can not include an actuator 160 coupled thereto, such that the printhead row of printheads 156 is fixedly secured relative to the remaining rows. In the present example, the plurality of printheads 156 in the first printhead row 155 and the plurality of printheads 156 in the third printhead row 256 each include a single actuator 160 coupled thereto, while the plurality of printheads 156 in the second printhead row 157 does not include an actuator 160. In this example, the plurality of printheads 156 in the first printhead row 155 and the plurality of printheads 156 in the third printhead row 256 are movable relative to the plurality of printheads 156 in the second printhead row 157. In particular, the actuators 160 coupled to the first printhead row 155 and the third printhead row 256 translate the plurality of printheads 156 in the first printhead row 155 and the third printhead row 256, respectively, in a direction transverse to the working axis 116 of the device 100 (i.e., in the + / -Y direction of the coordinate axis depicted in the figures).

[0199] In particular, actuation of the actuators 160 provides for a synchronized translation of the fixed configuration of the plurality of printheads 156 included in each of the first printhead row 155 and the third printhead row 256 relative to the plurality of printheads 156 in the second printhead row 157. In this example, the relative distance between each of the plurality of printheads 156 in the first printhead row 155 and the third printhead row 256 is maintained, such that the offset (i.e., pitch) between adjacent printheads 156 within the respective rows does not change as the printhead rows 155, 256 of printheads 156 are translated. In the present example, the plurality of printheads 156 in the first printhead row 155 are depicted as moving in the -Y direction of the coordinate axis, and the plurality of printheads 156 in the third printhead row 256 are depicted as moving in the +Y direction, while the plurality of printheads 156 in the second printhead row 157 disposed therebetween are depicted as fixed.

[0200] As the first printhead row 155 translates in the -Y direction and the third printhead row 256 translates in the +Y direction, and the second printhead row 157 maintains a fixed orientation therebetween, the effective print width of the printhead 254 can be increased. In other words, as one or more of the printhead rows 155, 157, 256 are coupled to at least one actuator 160, the printhead 154 of the print assembly can produce a variable print width that is configured to expand or contract the printhead rows 155, 157, 256 as needed. It should be appreciated that the direction and / or position of the translation of the first printhead row 155 and the third printhead row 256 can be interchangeable, and / or, at other angles than those shown and described herein.

[0201] Referring now to FIG. 16 In other embodiments, the second printhead row 157 of the plurality of printheads 156 can include an actuator 160 coupled thereto, while the plurality of printheads 156 in the first printhead row 155 and the third printhead row 256 do not include an actuator 160, respectively. In this example, the actuator 160 is configured to move the plurality of printheads 156 in the second printhead row 157 synchronously and independently of the non-movable printheads 156 in the first printhead row 155 and the third printhead row 256. It should be appreciated that other arrangements and combinations of actuators 160 coupled to more than one row of a print assembly can be incorporated herein without departing from the scope of the present disclosure. For example, a single actuator 160 can be coupled to the plurality of printheads 156 defining all three rows (i.e., the first printhead row 155, the second printhead row 157, and the third printhead row 256) such that actuation of the actuator 160 provides synchronous translation of all of the plurality of printheads 156 of the printhead 254 relative to the support carriage 152 (see FIG. 1B ) of the print assembly. It should be further appreciated that in other embodiments, additional rows of printheads 156 along the printhead 154, 254 can be included in the print assembly. Although the several row print assembly is identified herein as being positioned in a first, second, and third row in order relative to one another, it should be appreciated that the positions of the multiple rows of the print assembly can be interchangeable with one another such that various other arrangements and orientations of the multiple rows can be included within the printhead 154, 254 without departing from the scope of the present disclosure.

[0202] In some embodiments, the actuators 160 of the print head 254 are configured to move one or more of the plurality of print heads 156 in the first print head row 155, the second print head row 157, and / or the third print head row 256 in various other directions other than the directions shown and described above. For example, the actuators 160 of the print head 254 can be configured to move one or more of the plurality of print heads 156 in the first print head row 155, the second print head row 157, and / or the third print head row 256 in a direction parallel to the working axis 116 of the device 100 (i.e., in the + / -X direction of the coordinate axes depicted in the figures), in another direction transverse to the working axis 116 (i.e., in the + / -Z direction of the coordinate axes depicted in the figures), and / or the like. It will be appreciated that other combinations of print assemblies including more than one row of movable and fixed print heads 156 can be included in the print head 254 without departing from the scope of the present disclosure.

[0203] Reference is now made to FIGS. 17A-17G In some embodiments, the actuators 160 of the print assembly can include a fine actuator, a coarse actuator, and / or both. The fine actuator and the coarse actuator are each configured to move at least one print head 156 and / or the plurality of print heads 156 in a particular row (e.g., the first print head row 155) relative to the support carriage 152 of the print assembly in a direction transverse to the working axis 116 of the device 100 (i.e., in the + / -Y direction of the coordinate axes depicted in the figures). In particular, the fine actuator is operable to move the print heads 156 in the first print head row 155 with a degree of movement resolution that is greater than a degree of relative movement resolution of the coarse actuator. In other words, the fine actuator is configured to move the plurality of print heads 156 with a degree of fine movement resolution that provides a high-precision, precise movement tracking capability. The coarse actuator is configured to move the plurality of print heads 156 with a degree of coarse movement resolution that provides a lower-precision, large-stroke movement tracking capability that is relatively finer than the fine actuator. It will be appreciated that in some embodiments, a single actuator 160 can include both a fine actuator and a coarse actuator such that the actuator 160 is operable to move the print heads 156 in the first print head row 155 with both a degree of fine movement resolution and a degree of coarse movement resolution such that the actuator 160 provides both precise and large-stroke movement tracking capabilities.

[0204] The fine actuator can include various devices such as, for example, a piezoelectric linear positioner, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, a linear stage, a belt drive actuator, or any other actuator suitable for providing linear motion. The coarse actuator 164 can include various devices such as, for example, a magnetic linear drive, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, a linear stage, a belt drive actuator, or any other actuator suitable for providing linear motion. It should be appreciated that while the present example illustrates a fine actuator and a coarse actuator employed with the print assembly 150, the actuators can similarly be incorporated into other print assemblies including additional and / or fewer rows of printheads 156 without departing from the scope of the present disclosure.

[0205] The following figures and descriptions provide illustrative examples of print assemblies including at least one of a fine actuator or a coarse actuator and a corresponding degree of movement resolution of a plurality of printheads 156 in a printhead row 155 provided by the actuator.

[0206] With specific reference now to FIG. 17A As a first example, the print assembly 150 includes a fine actuator 162 coupled to a first printhead row 155 of the plurality of printheads 156 and a coarse actuator 164 coupled to a second printhead row 157 of the plurality of printheads 156. In this example, the fine actuator 162 is configured to move the plurality of printheads 156 in the first printhead row 155 in a degree of fine movement resolution in a direction transverse to the working axis 116 of the device 100. In particular, actuation of the fine actuator 162 provides for a translational incremental distance "A" of the plurality of printheads 156 in the first printhead row 155 in the +Y direction of the coordinate axes of the figure, the incremental distance "A" being approximately equal to one-third of the diameter of the ejection nozzle 158. In other words, the plurality of printheads 156 in the first printhead row 155 are laterally offset from a default position to an actuated position relative to the plurality of printheads 156 in the second printhead row 157, where the lateral offset is approximately one-third of the width of the ejection nozzle 158. It should be appreciated that the fine actuator 162 can be configured to translate the plurality of printheads 156 from the default position to the actuated position in various other incremental distances greater or less than the one-third distance "A" and in various other directions than the +Y direction illustrated and described herein.

[0207] With reference to FIG. 17BAs another example, the fine actuator 162 is coupled to the first printhead row 155 of the plurality of printheads 156 and is configured to move the plurality of printheads 156 in the first printhead row 155 in a direction transverse to the working axis 116 with a fine degree of movement resolution approximately equal to the incremental distance "B", which is approximately one-half the diameter of the ejection nozzle 158. In other words, the plurality of printheads 156 in the first printhead row 155 are laterally shifted from a default position to an actuated position relative to the plurality of printheads 156 in the second printhead row 157 by the fine actuator 162 with a lateral shift approximately one-half the width of the ejection nozzle 158. Although not shown, it should be appreciated that additional actuators, such as, for example, a coarse actuator 164 coupled to the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 can be included.

[0208] With reference to FIG. 17C As a further example, the fine actuator 162 is coupled to the first printhead row 155 of the plurality of printheads 156 and is configured to move the plurality of printheads 156 in the first printhead row 155 in a direction transverse to the working axis 116 with a fine degree of movement resolution approximately equal to the incremental distance "C", which is approximately one full diameter of the ejection nozzle 158. In other words, the plurality of printheads 156 in the first printhead row 155 are laterally shifted from a default position to an actuated position relative to the plurality of printheads 156 in the second printhead row 157 by the fine actuator 162 with a lateral shift approximately one full width of the ejection nozzle 158. It should be appreciated that the fine actuator 162 is configured to translate the plurality of printheads 156 from a default position to an actuated position with various other incremental distances greater than or less than the incremental distances shown and described herein and in various other directions. Although not shown, it should be appreciated that additional actuators, such as, for example, a coarse actuator 164 coupled to the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 can be included.

[0209] With reference now FIG. 17DIn this example, the coarse actuator 164 is configured to move the plurality of printheads 156 in the first printhead row 155 in a direction transverse to the working axis 116 of the apparatus 100 at a coarse movement resolution extent. In particular, actuation of the coarse actuator 164 provides for translation of the plurality of printheads 156 in the first printhead row 155 by an incremental distance "D" in the +Y direction of the coordinate axes of the figure, the incremental distance "D" being approximately equal to half the width of the printheads 156. In other words, the plurality of printheads 156 in the first printhead row 155 are laterally shifted from a default position to an actuated position relative to the plurality of printheads 156 in the second printhead row 157 by approximately half the width of the printheads 156. It will be appreciated that the coarse actuator 164 is configured to translate the plurality of printheads 156 from the default position to the actuated position by various other incremental distances greater or less than half distance "D", and / or in various other directions other than the +Y direction shown and described herein. Although not shown, it will be appreciated that additional actuators can be included, such as, for example, fine actuators 162 coupled to the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156.

[0210] With reference to FIG. 17E As another example, the coarse actuator 164 is coupled to the first printhead row 155 of the plurality of printheads 156 and is configured to move the plurality of printheads 156 in the first printhead row 155 in a direction transverse to the working axis 116 at a coarse movement extent resolution. In this example, the coarse movement extent resolution is equal to an incremental distance "E", the incremental distance "E" being approximately equal to the full width of the printheads 156. In other words, the plurality of printheads 156 in the first printhead row 155 are laterally shifted from a default position to an actuated position relative to the plurality of printheads 156 in the second printhead row 157 by the coarse actuator 164 by approximately one width of the printheads 156. Although not shown, it will be appreciated that additional actuators can be included, such as, for example, fine actuators 162 coupled to the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156.

[0211] With reference to FIG. 17FAs a further example, the coarse actuator 164 is coupled to the first printhead row 155 of the plurality of printheads 156 and is configured to move the plurality of printheads 156 in the first printhead row 155 in a direction transverse to the working axis 116 with a coarse degree of movement resolution. In this example, the coarse degree of movement resolution is equal to the incremental distance "F", which is approximately 1.5 times the width of a printhead 156. In other words, the plurality of printheads 156 in the first printhead row 155 are laterally shifted from a default position to an actuated position relative to the plurality of printheads 156 in the second printhead row 157 by the coarse actuator 164, where the lateral shift is approximately 150% of the width of a printhead 156. Although not shown, it should be appreciated that additional actuators, such as, for example, fine actuators 162 coupled to the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 can be included.

[0212] Referring to FIG. 17G As another example, the coarse actuator 164 is coupled to the first printhead row 155 of the plurality of printheads 156 and is configured to move the plurality of printheads 156 in the first printhead row 155 in a direction transverse to the working axis 116 with a coarse degree of movement resolution. In this example, the coarse degree of movement resolution is equal to the incremental distance "G", which is approximately the width of two printheads 156. In other words, the plurality of printheads 156 in the first printhead row 155 are laterally shifted from a default position to an actuated position relative to the plurality of printheads 156 in the second printhead row 157 by the coarse actuator 164, where the lateral shift is approximately 200% of the width of a printhead 156. It should be appreciated that the coarse actuator 164 is configured to translate the plurality of printheads 156 from a default position to an actuated position with various other incremental distances greater than or less than the incremental distances shown and described herein and in various other directions. Although not shown, it should be appreciated that additional actuators, such as, for example, fine actuators 162 coupled to the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 can be included.

[0213] Referring now to FIGS. 18A-18B and FIG. 24 a flowchart of an exemplary method 300 of actuating a number of printhead rows 155, 157 of a print assembly 150 when fabricating an object with a fabrication device 100 is schematically depicted. More particularly, movement of a number of printhead rows 155, 157 of a plurality of printheads 156 used to deposit a binding agent material 50 and / or other materials 114, 115 along a build area 120 serves to reduce the incidence of resolution defects on a printed object or part during an image transfer process due to a lack of jetting redundancy. FIGS. 18A-18B and FIG. 24The depiction and the following description accompanying the drawings are not meant to limit the subject matter described in this document or indicate how the material is to be deposited from the print assembly 150, but are meant to provide a simple, illustrative overview to illustrate the general movement of the plurality of print head rows 155, 157 of the print head 156 of the print assembly 150 to improve the jet redundancy described in this document.

[0214] Reference FIG. 18A At step 302, the computer-readable executable instructions stored within the non-transitory memory of the control system 10, when executed by the processor of the control system 10, transmit a signal to the first actuator assembly 102 to initiate movement of the print assembly 150 across the build area 120 in a first pass. In particular, the print assembly 150 translates across the rails 104 of the apparatus 100 and along the working axis 116 (see FIG. 1A ) thereby moving the print head 154 over the build area 120 in the +X direction of the coordinate axes in the figure. As the print head 154 of the print assembly 150 moves over the build area 120, the control system 10 sends signals to the plurality of print heads 156 in the first print head row 155 and the second print head row 157 to release material from the plurality of jet nozzles 158. The material (e.g., the adhesive material 50, the first material 114 from the first fluid reservoir 110, the second material 115 from the second fluid reservoir 112, etc.) is transported through the plurality of jet nozzles 158 in the plurality of print heads 156 in both the first print head row 155 and the second print head row 157 to the print head 154 and deposited onto the build area 120.

[0215] In the present example, the plurality of print heads 156 in the first print head row 155 and the plurality of print heads 156 in the second print head row 157 deposit material along the build area 120. As such, each of the plurality of jetting nozzles 158 from the plurality of print heads 156 in the first print head row 155 and the second print head row 157 can be mapped to a trajectory across the build area 120. The trajectory defines a plurality of pixels that can or can not receive deposited binder from one or more of the plurality of jetting nozzles 158 as the print assembly 150 traverses the build area 120. It should be appreciated that a "pixel" refers to a two-dimensional spatial portion of an object or part to be printed by the apparatus 100, in particular, a current slice or layer of a three-dimensional part relative to its positioning along the build area 120. Similarly, it should be appreciated that a "voxel" refers to a three-dimensional spatial portion of build material that, in combination with the binder, forms a physical portion of a part printed by the apparatus 100. In some embodiments, the plurality of pixels and / or voxels defining a spatial portion of build material 40 within the build area 120 can be defined based on a digital build file of a part to be built by the apparatus 100, such as a deposition pattern and / or apparatus control instructions defining stored and / or uploaded to the control system 10. The pixels of each build layer can be defined along a trajectory for the print assembly 150 to be configured to traverse over the build area 120. As such, the control system 10 can map one or more jetting nozzles to the trajectory and corresponding design deposition pattern for a current build layer such that the jetting nozzles deposit a prescribed volume of binder at prescribed sites on the build material 40 in the build area 120. As the print assembly 150 and / or print heads 156 are displaced, to achieve sub-pixel printing and / or jetting redundancy, the control system 10 remaps the trajectory to the jetting nozzle relationship, thereby associating the design deposition pattern defining the binder to be applied to the build material with new jetting nozzles aligned with their new trajectory across the build area 120 in response to the indexing operation.

[0216] Still referring to FIG. 18AWhen executed by the processor of the control system 10, the computer-readable executable instructions determine whether the print assembly 150 has reached a translation position 253 in the + / - X direction at or past an edge of the build area 120 where material is to be deposited in the build area 120 by the print assembly 150 in the first pass. As the print assembly 150 translates along the working axis 116 of the apparatus 100 (i.e., the +X direction of the coordinate axis of the figure) toward the translation position 253, the control system 10 determines whether the print assembly 150 has reached the translation position 253, for example, by monitoring the relative position of the print assembly 150 along the guide rail 104. In response to determining that the print assembly 150 is not positioned at the translation position 253, the control system 10 communicates a signal to the first actuator assembly 102 to continue translating the print assembly 150 past the build area 120 at step 302. The control system 10 further communicates a signal to the print assembly 150 to continue releasing material from the plurality of jetting nozzles 158 in the print heads 156 in the first print head row 155 and the second print head row 157.

[0217] Alternatively, in response to determining that the print assembly 150 is positioned at the translation position 253, the computer-readable executable instructions, when executed by the processor of the control system 10, communicate a signal to the print assembly 150 to terminate the release of material from the plurality of jetting nozzles 158 in the print heads 156 in the first print head row 155 and the second print head row 157. Additionally and / or concurrently, the control system 10 communicates a signal to the first actuator assembly 102 to terminate movement of the print assembly 150 along the working axis 116 by arresting actuation of the first actuator assembly 102. With the print assembly 150 positioned at the translation position 253, a plurality of pixels along the build area 120 have received material thereon from at least the first print head row 155 or the second print head row 157 during the first pass of the print assembly 150 over the build area 120 in the +X direction of the coordinate axis.

[0218] Reference is now made to FIG. 18B And at step 304, the control system 10 determines whether additional layer material (e.g., adhesive) is to be deposited and / or released from the print assembly 150. This determination by the control system 10 can be performed via various means and / or systems, such as, for example, by reference to a part to be built with the apparatus 100, by user input, image sensors, weight sensors, and the like. In response to determining at step 304 that no additional layer material (e.g., adhesive) is to be released from the print assembly 150, the control system 10 communicates a signal to the apparatus 100 to end the additive manufacturing process of the method 300 at step 306.

[0219] Alternatively, in response to determining at step 304 that additional layer material (e.g., adhesive) is to be deposited from the print assembly 150, at step 308 the computer-readable executable instructions, when executed by the processor of the control system 10, send a signal to the actuator 160 of the print assembly 150 to actuate at least one of the plurality of print heads 156 in the first print head row 155 and / or the second print head row 157 relative to the support carriage 152 (see FIG. 1B ) of the print assembly 150. In particular, actuation of at least one actuator 160 coupled to at least one of the first print head row 155 and / or the second print head row 157 of the plurality of print heads 156 is provided for translating the print heads 156 of said row relative to at least the print heads 156 of the other row in a direction transverse to the working axis 116 of the apparatus 100 (i.e., the + / - Y direction of the coordinate axis of the figure). In the present example, the print assembly 150 includes one actuator 160 coupled to the first print head row 155 of print heads 156 and one actuator 160 coupled to the second print head row 157 of print heads 156, enabling both print head rows 155, 157 to be moved relative to each other and relative to the support carriage 152 of the print assembly 150.

[0220] Still referring to FIG. 18B , the plurality of firing nozzles 158 of each of the plurality of print heads 156 included in the first print head row 155 and the second print head row 157 are repositioned from a default position to an actuated position (e.g., to an indexed position), the actuated position differing from the default position by at least some incremental distance (e.g., the incremental distances “A” to “G” of FIGS. 17A-17G ). Thereby, during a second pass of the print assembly 150 over the build area 120 (i.e., either a return pass over the current layer of powder or a new layer of powder applied on top of the previous layer), at least some pixels positioned along the build area 120 will receive material from at least one firing nozzle 158 that is different from the firing nozzle 158 that mapped to deposit material to said pixels during the first pass.

[0221] In some embodiments, during a first pass, the first pixel receives binder from a first jetting nozzle 158, and during a second pass, the first pixel receives binder from a second jetting nozzle 158, as a result of the one or more print heads 156 being repositioned between passes. In some instances, the first pass can be configured to deposit a first amount of binder, the first amount being a portion of a total amount prescribed for the portion of the powder within the current layer to receive, and the second pass can be configured to deposit a second amount of binder, the second amount being a remainder of the binder prescribed for the portion of the powder within the current layer to receive. As described above, the delivery of the first amount of binder can be achieved by the first jetting nozzle 158, and the delivery of the second amount of binder can be achieved by the second jetting nozzle 158.

[0222] It will be appreciated that by increasing the reliability with which the full resolution of each of the plurality of pixels on the build area 120 receives adequate material deposition, the lateral movement of the print heads 156 in the first print head row 155 and / or the second print head row 157 from the default positions relative to one another and to previous positions of the print head rows 155, 157 provides enhanced jetting redundancy in the manufacturing process.

[0223] It will be appreciated that in some embodiments, the movement of the print head rows 155, 157 of print heads 156 at step 308 can be any portion in which the control system 10 communicates signals to the actuators 160 to move the first print head row 155 and / or the second print head row 157 of print heads 156 relative to one another to randomly generated positions. In this embodiment, by repositioning the plurality of print heads 156 in each print head row 155, 157 in an uncalculated manner, jetting redundancy by the print assembly 150 is passively provided such that during a second pass of the print assembly 150, a plurality of pixels along the build area 120 are effectively aligned with randomly aligned jetting nozzles 158.

[0224] In other embodiments, movement of the print head rows 155, 157 relative to one another and relative to a previous position of the print head rows 155, 157 during the first pass of the print assembly 150 can be predetermined to predefined sites by the control system 10. In this example, the computer readable executable instructions, when executed by the processor of the control system 10, communicate signals to the actuators 160 to move the first print head row 155 and / or the second print head row 157 of the print heads 156 to a measurement position that varies relative to a previous position of the print head rows 155, 157 during the first pass. In this embodiment, by computationally repositioning the plurality of print heads 156 in each print head row 155, 157, active provision of jet redundancy by the print assembly 150 is provided such that during a second pass of the print assembly 150 that is intentionally varied from the first pass, a plurality of pixels along the build area 120 are specifically aligned with a jetting nozzle 158. For example, the control system 10 can communicate signals to the actuators 160 coupled to the print head rows 155, 157 to translate the print heads 156 in the print head rows 155, 157 in a manner that exchanges the position of the print head rows 155, 157 relative to one another.

[0225] The control system 10 can determine the computational position of the plurality of print heads 156 in the print head rows 155, 157 through various systems such as, for example, camera images, sensor outputs, calibration patterns, and the like. In any example, movement of the print head rows 155, 157 of print heads 156 for a second pass of the print assembly 150 (i.e., a return pass over a current layer of powder or a new layer of powder applied on top of a previous layer) provides enhanced material jet redundancy of the manufacturing process by increasing the full resolution of each of the plurality of pixels on the build area 120 from more than one jetting nozzle 158 receiving adequate material deposition thereon. It should be appreciated that in other embodiments, movement of the plurality of print heads 156 in the first print head row 155 and / or the second print head row 157 can occur prior to the first pass of the print assembly 150 over the build area 120 at step 302.

[0226] Turning now to FIGS. 21A-22B , further embodiments and functionality of the apparatus 100 are depicted and described. For example, FIGS. 21A-21E Techniques implementing sub-jet pitch indexing of a print assembly are depicted and described to enable low resolution print heads to operate and deliver material, such as a binder, to a powder layer at increased resolution, further improving green part strength uniformity and finer geometries of the built part. Due to the discrete fixed geometry of inkjet heads configured to dispense a binder, binder jetting printing generally applies binder in discrete increments. However, the embodiments described herein provide for binder to be delivered to a build material 40 (FIG. 1B Systems and methods for gray scale based sub-pixel deposition on (e.g., powder) to remove limitations of inkjet head geometry.

[0227] In one example, the apparatus can be equipped with a print head 156 configured to deliver a drop of binder material at 400 DPI (dots per inch) intervals along the latitudinal axis. However, by enabling the print assembly 150 to be carried with the second actuator assembly 103, the print assembly can be configured to deliver multiple drops of binder material at much finer increments between successive passes along the longitudinal axis by implementing a sub-pixel indexing distance of the print assembly 150. For example, a 400 DPI print head can be configured to distribute multiple drops of binder between two passes along the longitudinal axis to achieve the equivalent of an 800 DPI print head by implementing a sub-ejection pitch indexing of the print assembly 150 of about one-half the ejection pitch.

[0228] In other words, the spacing between adjacent ejection nozzles 158 is fixed, and thus there is a fixed pitch between the placement of binder across a layer of powder in a single pass. However, by implementing a mechanical shift of the print assembly 150 (e.g., what is referred to herein as "indexing" along the latitudinal axis), a corresponding indexing of the ejection nozzles 158 is achieved, and a second deposition of binder on the same or a subsequent layer of powder can be performed, thereby increasing the resolution at which binder can be deposited. Correspondingly, build instructions generated for a build part can define pixels having sub-pixels with a resolution that is higher than the mechanical resolution defined by the ejection pitch (d). The ejection pitch (d) is the lateral distance from center to center between adjacent ejection ports in the same row of print heads.

[0229] To achieve printing of a design deposition pattern (e.g., 125) with a higher resolution than the mechanical resolution defined by the ejection pitch (d) of the print assembly, a latitudinal indexing of the print assembly 150 between passes on the build area 120 is implemented, as shown and described herein. FIG. 21C

[0230] In further embodiments, the method of implementing a random redundancy within a build enabled by the second actuator assembly 103 configured to index the print assembly 150 along the latitudinal axis enables the reduction or removal of compounded effects of failed ejection ports. Such embodiments are described in more detail with reference to FIGS. 22A-22B

[0231] ​​Suitable actuators can include, but are not limited to, linear stages, worm drive actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, electromechanical linear actuators, and the like. By way of example, the second actuator assembly 103 can include a linear stage actuator, such as a 150 MM linear motor stage with at least 4 um accuracy. In some examples, the first actuator assembly 102 and / or the second actuator assembly 103 can include a position sensor 102a and / or 103a, respectively, that provides position information to the electronic control unit in a feedback control signal, such that the electronic control unit can track the position of the print assembly 150 in response to the provided control signal. In some examples, the electronic control unit can adjust the control signal provided to the first actuator assembly 102 and / or the second actuator assembly 103 based on the position information provided by the position sensor 102a and / or 103a. In embodiments, the position sensor 102a and / or 103a can be an encoder, an ultrasonic sensor, an optical-based sensor, a magnetic force sensor, or the like, embedded or coupled to the first actuator assembly 102 and / or the second actuator assembly 103.

[0232] Turning now to FIGS. 21A-21E , the print assembly 150 is depicted as implemented with the second actuator assembly 103 for weft axis indexing. As referenced above, the first actuator assembly 102 can be implemented with the print assembly 150 for warp axis indexing. FIGS. 17A-17GThe described functionality, print assembly 150 can be configured to be indexed (e.g., moved laterally relative to the latitudinal axis) while using an actuator to offset one or more of the plurality of print heads 156, or independently of whether the plurality of print heads 156 are capable of being moved or are moved. That is, in some embodiments, print assembly 150 is movably coupled to support bracket 152 via second actuator assembly 103. When directed, for example, by electronic control unit, second actuator assembly 103 moves print assembly 150 along the latitudinal axis by an indexing distance. As described in greater detail herein, the term "indexing distance" can refer to a fractional portion of the ejection pitch (d), an integer multiple of the fractional portion of the ejection pitch (d), or a multiple (e.g., 1.1x, 1.2x, 1.3x, 1.4x, 1.5x, 1.6x, 1.7x, 1.8x, 1.9x, 2x, 3x, 4x, 5x, 6x, 7x, 8x, 9x, 10x, 50x, 75x, 100x, 200x, 500x, or more of the ejection pitch (d) units). In some embodiments, the indexing distance can be, for example, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, or more or a value between 1.1x and 500x or more. In some embodiments, the indexing distance can be 5 mm to 20 mm, or any value therebetween.

[0233] As referenced above, the space from one ejection nozzle 158 to an adjacent ejection nozzle 158 defines an ejection pitch (d) in relation to an image pixel. To increase the resolution of a deposition pattern (e.g., 125, 126, or 127, respectively) of a binding agent across a build material (e.g., powder) having a layer of powder on build area 120, FIGS. 21C-21E ) along the longitudinal axis between successive passes in opposite directions by a sub-ejection pitch indexing distance, print assembly 150 containing the plurality of print heads 156 and the plurality of ejection ports.

[0234] For example, for a first pass along the working axis (i.e., the longitudinal axis), print assembly 150 can be indexed at position I0, and a second pass, for example, in an opposite direction to the first pass, can be indexed to position Ii as depicted in FIG. 21A and FIG. 21B . The indexing distance (i.e., the distance from position I0to position Ii can be a non-integer multiple of the ejection pitch (d), for example, 1 / 10X, 1 / 5X, 1 / 4X, 1 / 3X, 1 / 2X, or any distance greater than zero and less than the ejection pitch (d).

[0235] FIG. 21CA top view depicting a build area 120 having a layer of powder (e.g., build material 40) deposited therein, and an illustrative representation of a design deposition pattern 125 defining a pixel 180 and sub-pixels 181A-181F, the numerical values depict drop volumes, the illustrative gray scale values amount to the amount of binder to be deposited at the predefined sites. As used herein, "gray scale value" refers to an integer multiple of the smallest unit of drop volume that the print head is capable of achieving. FIG. 21C Further depicted are print assemblies 150 having a plurality of ejection nozzles 158-1 through 158-8. The print assembly 150 located at the top of the figure is positioned at a location I0, where the plurality of ejection nozzles 158-1 through 158-8 are mapped to traverse a first travel trajectory across the build area 120. The print assembly 150 located at the bottom of the figure has been indexed by an index distance to a location II, where the plurality of ejection nozzles 158-1 through 158-8 are mapped to traverse a second travel trajectory across the build area 120.

[0236] The center sites of a pixel 180 and adjacent pixels correspond to an ejection pitch (d) of one ejection nozzle 158 to an adjacent ejection nozzle 158. In view of the fact that the centers of sub-pixels 181A-181F can be defined within the build instructions as increments of the ejection pitch (d), one or more sub-pixel centers 181A-181F are optionally defined within a pixel 180. The sub-pixels 181A-181F can further be assigned a drop volume of binder to be dispensed for deposition by the ejection nozzles 158 during a build operation. The size (or footprint) of a sub-pixel can depend on the drop volume of a micro-droplet of binder to be deposited on a corresponding portion of a layer of powder (e.g., build material 40) to which the center 181A-181F of the sub-pixel is mapped according to the design deposition pattern 125. In some embodiments, the size of a sub-pixel can be based on the speed at which the print assembly 150 traverses the build area 120, the nature or type of build material 40 FIG. 1B ), the temperature of the build environment, and the like.

[0237] Still referring to FIG. 21Csub-pixel 181B along the first pass trajectory and a second volume of binder within a second sub-pixel 181E along a second pass trajectory that is indexed from the first pass trajectory by an indexing distance that is greater than zero and less than the ejection pitch (d). As the binder droplets traverse the build area 120, the binder droplets make a spot with the build material 40 having a size or diameter corresponding to the ejection nozzle 158. However, in some examples, the release of the binder droplets from the ejection nozzle 158 must take into account the speed at which the print assembly 150 is moving, as the trajectory of the droplet includes a velocity vector in the direction of the print assembly 150 and a velocity component in the direction from the ejection nozzle to the build material as the droplet travels from the ejection nozzle 158 to the build material 40. That is, depending on the speed at which the print assembly 150 traverses the build area 120, compensation can be needed with respect to where the binder is released relative to where the binder is intended to affect the build material.

[0238] Turning to FIG. 21D , a diagrammatic deposition pattern 125A is depicted resulting from the deposition of binder according to the design deposition pattern depicted in FIG. 21C . As the binder disperses within the build material 40, the binder can overlap with binder and powder within adjacent sub-pixels. Additionally, as the binder disperses, the binder can infiltrate and / or wick into and / or throughout the volume of the porous layer of powder defining the voxel 30( FIG. 1A ). Depending on the droplet volume of the droplets of binder, the thickness of a layer of powder (depth along the Z-axis), the density of the powder, and other variables, the binder can disperse into lower layers of powder, further solidifying the lower layers to the upper layer. It is to be understood that once the binder has finished wicking and / or solidifying, the part

[0239] While a predefined amount of binder for a pixel can be deposited within the pixel at one time during a single pass, by dividing the predefined amount of binder for a pixel into one or more sub-pixel blocks during one or more passes of the print assembly 150, the binder can be more evenly integrated with the build material (e.g., powder) of adjacent voxels in the build area 120 with indexing of the print assembly 150 between passes.

[0240] Referring to FIG. 21E , another diagrammatic build area 120 is depicted in which FIG. 21CThe same droplet volume depicted for each pixel 180 is now applied using adhesive at varying locations within pixel 180 using several smaller droplet volumes. For example, in FIG. 21C In the design, the deposition pattern 125 specifies a large droplet volume (3) in a single site shown in sub-pixel 182B, while the same layer is used for construction. FIG. 21E The design deposition pattern 126 depicted now defines three smaller droplet volumes of adhesive for placement in three distinct sub-pixels 182A-182C within pixel 180 during the traverse of the first travel path of the printing assembly 150. Each of the three smaller droplets can be one-third the volume of a larger droplet. In other words, three unit droplet volumes defined for allocation at one site within a pixel can be allocated into one unit droplet volume, the center of which is located at three distinct sites within the same pixel, as when... FIG. 21C Depositional patterns 125 and FIG. 21E This is demonstrated when comparing the deposition pattern 126. The size or amount of the applied binder can be proportional to the volume of a voxel, which is partially defined by a pixel, also known as an area of ​​influence of droplets in the powder. The amount of binder applied to a particular pixel can be determined based on the desired saturation of that particular pixel. The desired saturation of a particular pixel can be determined based on the location of the pixel relative to the edge of the part being constructed and / or the number of vertically adjacent layers to be constructed on top of the particular pixel.

[0241] Go to FIG. 21F ,according to FIG. 21D The design deposition pattern depicted herein illustrates a deposition pattern 126A resulting from binder deposition. Again, as the binder is dispersed within the build material 40, the binder may overlap with binder and powder within adjacent sub-pixels. Additionally, during binder dispersion, the binder may penetrate and / or wick to and / or spread throughout the defined voxel 30 ( FIG. 1A The volume of the porous layer of powder is determined by the droplet volume of the adhesive microdroplets, the thickness of a powder layer (depth along the Z-axis), the powder density, and other variables. The adhesive can be dispersed into a lower powder layer, which then cures the lower layer onto the upper layer. When combined with... FIG. 21D View the applied deposition pattern 125A together FIG. 21F When the applied deposition pattern 126A is applied, it can be observed that a more uniform distribution of the adhesive can be achieved by further varying the droplet volume and droplet site. This is possible because the jet nozzle can be shifted by the sub-jet spacing shift distance between strokes. It should be understood that the shifting of the jet nozzle can be achieved by shifting the individual printheads and / or shifting the printing assembly 150.

[0242] More specifically, this is achieved through fine and coarse motion control of the print assembly provided by a printhead position control assembly, which includes a first actuator assembly 102 configured to move the print head along a longitudinal axis and a second actuator assembly 103 configured to move the print head along a latitudinal axis. FIG. 21G A further example of a deposition pattern of the binder material on the build area 120 using a combination of large and small droplets at the varying sites within the pixel is provided.

[0243] In further embodiments of the apparatus, the print assembly 150 can be indexed between passes on a single layer of powder or between multiple layers of powder to randomize sites of malfunctioning jetting nozzles 158 or print heads 156. Indexing can be achieved by moving the print assembly 150 along the latitudinal axis with the second actuator assembly 103. The indexing motion of the print assembly 150 can be predetermined by the slicing engine when determining the deposition pattern for building the part, or instantaneously by the electronic control unit of the apparatus, for example, when a malfunctioning jetting nozzle 158 or print head 156 is detected. The advantage of predetermining the random indexing of the print assembly 150 with the slicing engine is that the association of jetting nozzles 158 with various trajectories along the longitudinal axis can be known through the build process of the part. For example, assuming that one or more jetting nozzles or print heads have malfunctioned during the build process, a history of jetting nozzle 158 and trajectory alignment for each pass during the build process can be generated and used for post-production analysis of the part.

[0244] The term "predefined random indexing" or "predefined random indexing performed" as used herein refers to a random indexing value defined by the slicing engine when developing executable instructions for the apparatus to perform during the build. Further, the term "predefined" refers to the pre-planning of the indexing of the print assembly 150 by the slicing engine, and the term "random" refers to the aspect that the amount by which the print assembly 150 is indexed in one instance can be different than the amount by which the print assembly 150 is indexed in a second instance, and can be unconstrained by any functional relationship other than, for example, the build size of the part. That is, if the build size of the part has a build width of 100 units and the print assembly 150 has nozzles 158 positioned along the latitudinal axis to cover up to a build width of 150 units, then a randomly selected indexing value can be 1 to 50 units, such that the entire build width on which the binder is deposited on the build area during a pass of the print assembly can be associated with the jetting nozzles 158. The term "unit" as used herein can refer to any known unit of measurement used by the apparatus, for example, inches, meters, millimeters, etc. Additionally, the unit values used herein are for explanatory purposes only and are not intended to limit the disclosure.

[0245] Further, the random nature of the indexing of the print assembly 150 can be determined by the slicing engine such that a jetting nozzle corresponding to a first pass trajectory along the longitudinal axis during a first pass can be randomly assigned to a second pass trajectory along the longitudinal axis during a second pass (e.g., a subsequent pass relative to the first pass). It will be appreciated that indexing of the print assembly 150 can not be performed between every pass of the print assembly 150 over the build area 120. However, in some examples, when developing the executable instructions, the slicing engine can be configured, e.g., by an engineer or operator, to include indexing commands or steps between every subsequent pass of the print assembly 150 over the build area, or at a less frequent interval, such as every other pass, every two passes, or any randomly selected number of passes between 1 and the total number of passes defined for the build part.

[0246] In some examples, the electronic control unit of the apparatus 100 can be configured to perform indexing of the print assembly 150 independently of the predefined random indexing determined by the slicing engine. That is, the electronic control unit of the apparatus 100 can implement indexing operations of the print assembly 150 “on the fly” between passes. Such operations can be triggered by a sensor or other indication of a malfunctioning print head or jetting nozzle. However, in some examples, the electronic control unit can implement a random amount of indexing of the print assembly 150 after a predetermined number of passes over the build area 120.

[0247] Referring to FIG. 22A and FIG. 22B , an illustrative depiction of indexing of the print assembly 150 with malfunctioning jetting nozzles 195a and 195b is shown. As FIG. 22A depicted in FIG. 1 1 1, the malfunctioning jetting nozzles 195a and 195b are unable to deposit binder along corresponding trajectories 190a and 190b, respectively, as the print assembly 150 traverses the build area 120 having a first layer of powder. However, during a subsequent pass (which can be a return pass along the same layer, or a pass over a subsequently laid layer of powder), the print assembly 150 is indexed by an indexing distance, e.g., a distance of one or more jetting pitches (d) (i.e., the pitch from one jetting nozzle to an adjacent jetting nozzle), such that the malfunctioning jetting nozzles correspond to different trajectories. Prior to traversal of the build area by the print assembly 150, the control system 10 maps build instructions defining pixels in a deposition pattern to jetting nozzles 158 configured to traverse the build area 120 based on their planned trajectories such that the jetting nozzles 158 are configured to deposit binder in accordance with build instructions associated with their current latitudinal position along the latitudinal axis.

[0248] After at least one pass over build area 120, the control system can execute instructions in the build instructions to cause print assembly 150 to index by a predefined random index, causing ejection nozzles 158 of print assembly 150 to move a lateral distance in a first direction along a latitudinal axis. Now that ejection nozzles 158 are aligned with a new trajectory over build area 120, control system 10 remaps the build instructions used to define pixels in the deposition pattern to ejection nozzles configured to traverse build area 120 based on their new trajectory after indexing, such that ejection nozzles 158 are configured to deposit binder according to build instructions associated with their current latitudinal position along the latitudinal axis. The remapping of the deposition pattern includes digitally shifting the deposition pattern in a second direction opposite the first direction in which ejection nozzles were indexed, such that ejection nozzles can be assigned build instructions for a portion of the part corresponding to their new trajectory after being indexed. In other words, in response to the mechanical shift in the first direction, a digital shift in the second direction opposite the first direction but by the same absolute amount is needed to continue building the part over build area 120.

[0249] Turning to FIG. 22B , the first failed ejection nozzle 195a is now positioned along a non- build trajectory (not used for subsequent passes), and the second failed ejection nozzle 195b now corresponds to a different trajectory 191 after mechanical indexing of print assembly 150 and / or individual print heads 156. The different active ejection nozzle 158 now corresponds to the previous trajectory 190b previously executed by the second failed ejection nozzle 195b, which now receives binder from active ejection nozzle 158 instead of being further deprived of binder, assuming the failed ejection nozzle 195b subsequently traverses the same trajectory. The random shifting of multiple ejection ports relative to trajectories along the longitudinal axis minimizes repeated passes of failed ejection ports over particular portions of the build area, thereby improving the resulting green strength and integrity of the part. That is, the active ejection port can apply binder to the trajectory that the failed ejection port was unable to apply binder to in previous passes.

[0250] In operation, control system 10 maps build instructions used to define pixels in the deposition pattern to ejection nozzles 158 configured to traverse build area 120 based on their planned trajectory, such that ejection nozzles 158 are configured to deposit binder according to build instructions associated with their current latitudinal position along the latitudinal axis. Moreover, while the print head traverses along the longitudinal axis to apply binder, control system 10 of apparatus 100 can cause a selected ejection nozzle of the plurality of ejection nozzles to dispense more than one drop of binder on a layer of powder based on the deposition pattern defined by the slicing engine, where a first ejection port of the plurality of ejection ports corresponds to a first pass trajectory assigned by the slicing engine.

[0251] Then, the control system 10 of device 100 can rotate the printhead along the latitudinal axis by an integer number of pixels, such that the first ejector nozzle corresponds to the second trajectory and the other ejector nozzle corresponds to the first trajectory assigned by the slicing engine, subsequently causing the rotated printhead to move laterally along the longitudinal axis and apply adhesive to the powder layer in a deposition pattern defined by the slicing engine. In response to the rotation, the control system 10 remaps the build instructions for defining the pixels in the deposition pattern to the ejector nozzle 158, which is configured to traverse the build region 120 based on its new trajectory, such that the ejector nozzle is configured to deposit adhesive after rotation according to the build instructions associated with its current latitudinal position along the latitudinal axis.

[0252] In some embodiments, an image processing device 14 may be used. FIG. 1B (e.g., an in-situ monitoring system) examines the build area between strokes to determine if the printhead or jet nozzles are malfunctioning by identifying the tracks where a predefined amount of adhesive has been received or not received. The electronic control unit (ECU) can then be configured to adjust the prescribed tracks of the jet nozzles identified as malfunctioning in subsequent build strokes to minimize the impact of the malfunctioning jet nozzles on the overall build. More specifically, the in-situ monitoring system is configured to identify the malfunction of one or more jet nozzles out of a plurality of jet nozzles and provide a notification signal to the ECU, identifying the one or more malfunctioning jet nozzles. The ECU can then develop one or more shift commands to shift the printhead between predefined strokes such that the malfunctioning jet nozzle is configured not to cross the same track during subsequent strokes while being determined to be malfunctioning.

[0253] Previous embodiments describe and depict systems and methods for controlling the application of adhesives or other materials to build areas, with additional control of the printing assembly 150 implemented by a second actuator assembly 103, which controls the positioning of the printing assembly 150 along the latitudinal axis. A further consideration when applying adhesives is the leakage effect. That is, adhesive jet printing involves depositing multiple drops of liquid adhesive layer by layer into the powder. The multiple drops of adhesive penetrate the powder and undergo a phase change (curing) to bond the powder particles together layer by layer. However, when the rate of increase in the build layer becomes desired, the deposited adhesive may not have enough energy and / or time to undergo a phase change before additional adhesive can be added in subsequent printed layers. That is, the adhesive curing time may be rate-limiting. This causes the adhesive to flow downward beyond the layer in which it is deposited. Printed geometries with blocks having a downward-facing surface have the risk of blocks becoming overly wet, resulting in surface defects and weak green strength.

[0254] The following provides a solution to the issue of adhesive bleed by controlling the amount of adhesive deposited in vertically adjacent layers having one or more layers applied thereon (along the Z-axis). Turning now to FIGS. 23A-23B , the apparatus 100 can be configured to deposit an increasing amount of adhesive in vertically adjacent layers such that adhesive bleed between the layers does not negatively affect the facing down surface of the part and / or the green strength of the part. FIG. 23A An illustrative part 200 is depicted for construction with the apparatus 100. FIG. 23B A cross-section of the part 200 is depicted represented by the build layer 210 and the portion 220 of each layer.

[0255] A slicing engine or similar tool configured to generate executable instructions defining print head movements, design deposition patterns, and amounts of adhesive or other materials can define the layer-to-layer amount of adhesive to apply to the vertically adjacent portion 220 of powder, estimating the voxel when the adhesive is received. The amount of adhesive applied to the vertically adjacent portion 220 of powder can be defined by a total number of adjacent layers within a decay length. For example, a first portion of powder in a stack of several layers (e.g., 2 or more layers, 3 or more layers, 4 or more layers, 5 or more layers) can receive a first amount of adhesive that is less than the amount of adhesive deposited in a second portion of powder positioned above the first voxel. The amount of adhesive deposited in voxels of powder vertically aligned in subsequent layers of powder is gradually increased to a predetermined volume. In some embodiments, the amount of adhesive dispensed in portions 220 of powder vertically aligned in subsequent layers of powder is gradually increased beyond a decay length defined by a predetermined number of layers of powder. Similarly, the amount of adhesive dispensed in portions 220 of powder vertically aligned in subsequent layers of powder can be gradually increased beyond a decay length defined by a predetermined number of layers of powder when the predetermined number of layers is greater than a predetermined thickness threshold. That is, the slicing engine can be configured to apply bleed control only for layers having a greater than a predetermined thickness threshold (i.e., greater than a predetermined number of layers).

[0256] The amount of adhesive dispensed in portions of powder vertically aligned in subsequent layers of powder can be based on one or more characteristics. These can include, but are not limited to, characteristics of the powder material, such as the bulk density of the powder material, the amount of time the adhesive wicks before setting or solidifying, the type of adhesive or the type of powder, the exposure time of a solidification energy source (e.g., infrared, ultraviolet, or other energy source), and / or other characteristics.

[0257] In operation, the control of adhesive bleed disclosed herein enables the apparatus to apply more layers of a build more efficiently, at a faster pace, without being limited by the solidification rate of the adhesive.

[0258] Referring back to FIG. 24When the processor of the controlled system 10 executes, computer-readable and executable instructions cause method 300 to return to step 302, repeating the steps shown and described herein for the second stroke (e.g., a return stroke on the current layer of powder on build region 120). Specifically, when the processor of the controlled system 10 executes, computer-readable and executable instructions signal the first actuator assembly 102 of the device 100 to translate the printing assembly 150 from translation position 253 to original position 151, such that the printhead 154 moves on build region 120 during the second stroke. When the processor of the controlled system 10 executes, computer-readable and executable instructions signal the printhead 154 to release material from the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157, thereby depositing additional material onto the pixels of build region 120 as the printhead 154 moves on build region 120 during the second stroke. Thus, in this example, as the additional material is released from the printhead 154 during the second stroke, the printhead 154 moves from the translational position 253 to the original position 151 on the build area 120.

[0259] In other embodiments, the control system 10 signals the first actuator assembly 102 of the device 100 to translate the printing assembly 150 from the translation position 253 to the original position 151 before initiating the second stroke, such that during the second stroke, the print head 154 again moves from the original position 151 to the translation position 253 on the build area 120. In this example, the print head 154 moves from the original position 151 to the translation position 253 on the build area 120 as additional material is released from the print head 154 during the second stroke. The control system 10 repeats the steps described in detail above until the three-dimensional part to be printed by the device 100 is complete and there is no additional material to be deposited in step 306.

[0260] Although this example of exemplary method 300 depicts and describes the printing assembly 150 of device 100 initially positioned at its original position 151 before moving to translation position 253, and the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 in the actuated position ( FIG. 18B Previously arranged in the default position ( FIG. 18AHowever, it should be understood that, without departing from the scope of this disclosure, in other embodiments, the printing assembly 150 may initially be positioned at translational position 253, with the plurality of printheads 156 in the printhead rows 155, 157 arranged in an actuated position. Furthermore, it should be understood that the exemplary method 300 described and illustrated herein can be implemented by various other printing assemblies besides the printing assembly 150, such as, for example, the three-row printing assembly described above. It should be further understood that, in some embodiments, one or more steps of the method 300 described above may be adjusted, varied, and / or entirely omitted, including but not limited to the steps of: releasing material from the plurality of jet nozzles 158 onto the plurality of pixels of the build area 120, determining whether the printing assembly 150 is in translational position 253, stopping the release of material from the plurality of jet nozzles 158, stopping the movement of the printing assembly 150, etc.

[0261] Now for reference FIGS. 18A-18B Together FIG. 25 Together with the flowchart, an exemplary method 400 is schematically depicted in which a plurality of printhead rows 155, 157 of a printing assembly 150 are actuated during the construction of an object in a manufacturing apparatus 100. More specifically, the movement of a plurality of printhead rows 155, 157 of a plurality of printheads 156 for depositing adhesive material 50 and / or other materials 114, 115 along a build area 120 is used to reduce the incidence of resolution defects on the printed object or part during image transmission processing due to a lack of jet redundancy. Figure 18 and FIG. 25 The descriptions herein and the accompanying descriptions are not intended to limit the subject matter described herein or to represent an exact description of how material is deposited from the printing assembly 150, but are intended to provide a simple schematic overview to illustrate the general movement of the plurality of printhead rows 155, 157 of the printhead 156 of the printing assembly 150, thereby improving the jetting redundancy described herein.

[0262] refer to FIG. 18AAt step 402, the computer-readable executable instructions, when executed by the processor of the controlled system 10, transmit a signal to the first actuator assembly 102 to cause the print assembly 150 to move over the build area 120 in a first pass. In particular, the print assembly 150 translates across the rails 104 of the apparatus 100 and along the work axis 116, thereby moving the print head 154 over the build area 120 in the +X direction of the coordinate axes in the figure. As the print head 154 of the print assembly 150 moves over the build area 120, the controlled system 10 sends signals to the plurality of print heads 156 in the first print head row 155 and the second print head row 157 to release material from the plurality of ejection nozzles 158. The material (e.g., the binder material 50, the first material 114, the second material 115, etc.) is transported to the print head 154 by the plurality of ejection nozzles 158 in the plurality of print heads 156 in both the first print head row 155 and the second print head row 157 and deposited onto the build area 120.

[0263] In the present example, the plurality of print heads 156 in the first print head row 155 and the plurality of print heads 156 in the second print head row 157 deposit material along the build area 120. As such, at least some of the plurality of ejection nozzles 158 from the plurality of print heads 156 in the first print head row 155 and the second print head row 157 eject material over at least one pixel positioned along the build area 120. In this example, the plurality of print heads 156 in the first print head row 155 and the second print head row 157 are in a default position relative to one another as the print assembly 150 deposits material onto the build area 120 of the apparatus 100. As will be described in greater detail herein, in other embodiments, the plurality of print heads 156 in the first print head row 155 can deposit a different material than the plurality of print heads 156 in the second print head row 157 (see FIG. 27 ).

[0264] Still referring to FIG. 18AWhen executed by the processor of the control system 10, the computer-readable executable instructions determine whether the print assembly 150 has reached a translation position 253 in the + / - X direction at or past an edge of the build area 120 where material is to be deposited in the build area 120 by the print assembly 150 in the first pass. As the print assembly 150 is translated along the working axis 116 of the apparatus 100 (i.e., the +X direction of the coordinate axis in the figure), the control system 10 determines whether the print assembly 150 has reached the translation position 253, for example, by monitoring the relative position of the print assembly 150 along the guide rail 104. In response to determining that the print assembly 150 is not positioned at the translation position 253, the control system 10 transmits a signal to the first actuator assembly 102 to continue translating the print assembly 150 past the build area 120 at step 402. The control system 10 further transmits a signal to the print head 154 to release material from the plurality of nozzles 158 in the print heads 156 in the first print head row 155 and the second print head row 157.

[0265] Alternatively, in response to determining that the print assembly 150 is positioned at the translation position 253, the computer-readable executable instructions, when executed by the processor of the control system 10, transmit a signal to the print head 154 to terminate the release of material from the plurality of ejection nozzles 158 in the plurality of print heads 156 in the first print head row 155 and the second print head row 157. Additionally and / or synchronously, the control system 10 transmits a signal to the first actuator assembly 102 to terminate movement of the print assembly 150 along the working axis 116 by arresting actuation of the first actuator assembly 102. With the print assembly 150 positioned at the translation position 253, a plurality of pixels positioned along the build area 120 have received material thereon from at least the first print head row 155 or the second print head row 157 during the first pass of the print assembly 150 over the build area 120 in the +X direction of the coordinate axis.

[0266] Reference is now made to FIG. 18B And at step 404, the control system 10 determines whether adhesive or other material is to be deposited from the print assembly 150. This determination by the control system 10 can be made via the various means and / or systems described in detail above. In response to determining at step 404 that no additional layer of material (e.g., adhesive) is to be deposited from the print assembly 150, the control system 10 transmits a signal to the apparatus 100 to end the additive manufacturing process of the method 400 at step 406, if the part being built is complete.

[0267] Alternatively, in response to determining at step 404 that additional layer material (e.g., adhesive) is to be deposited from the print assembly 150, at step 408, the computer readable executable instructions, when executed by the processor of the control system 10, transmit a signal to the image processing device 14 (see FIG. 1B ) of the apparatus 100 to scan the build area 120. In particular, the image processing device 14 captures one or more images of the three-dimensional part being produced by the apparatus 100 along the build area 120 to identify the gradual development of the part during the additive manufacturing process. The image processing device 14 is positioned above the build area 120 (i.e., in the +Z direction of the coordinate axis of the figure) to effectively image the part being printed (see FIG. 1B ). The image processing device 14 can include various devices or systems capable of producing a visual reproduction of the contents positioned within the focal range of the device 14.

[0268] Referring back to FIG. 25 , at step 410, utilizing the image scan of the build area 120 captured by the image processing device 14, the computer readable executable instructions, when executed by the processor of the control system 10, map the plurality of pixels positioned along the build area 120. In particular, based on the image scan produced by the image processing device 14, each of the plurality of pixels along the build area 120 is mapped to determine the print / production progress of the three-dimensional part. In this example, the control system 10 can identify the build characteristics of a particular pixel along the build area 120 to determine whether any pixel has not adequately received material thereon. For example, a pixel can have been aligned with a particular jetting nozzle 158 that did not effectively deposit material at the pixel during a previous pass (e.g., a first pass) of the print assembly 150. For example, a jetting nozzle 158 that can have experienced a misfire or clog during a previous pass can have been prohibited from depositing an adequate amount of material to one or more pixels aligned with the jetting nozzle 158 due to the relative position of the print head row 155, 157 that includes the jetting nozzle 158.

[0269] Thus, the computer readable executable instructions, when executed by the processor of the control system 10, perform the mapping of the plurality of pixels to identify the necessary development of the part at each of the plurality of pixels. By mapping the plurality of pixels and determining the gradual development of the part at each pixel up to the present time, the control system 10 of the apparatus 100 can adjust the position and / or arrangement of the plurality of print heads 156 of the print assembly 150 for a subsequent pass (e.g., a second pass) to increase the likelihood that the plurality of pixels receive an adequate amount of material disposed thereon from one or more different jetting nozzles 158 of the plurality of jetting nozzles 158.

[0270] Referring back to FIG. 18BAt step 412, the computer-readable executable instructions, when executed by the processor of the controlled system 10, transmit signals to at least one actuator 160 of the printhead 154 to actuate at least one of the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 relative to one another. In particular, the actuation of the first printhead row 155 and / or the second printhead row 157 is based on the mapping of the plurality of pixels at step 410. The actuation of the at least one actuator 160 coupled to at least one of the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 provides for translation of the printheads 156 of the row relative to at least the other row of printheads 156 in a direction transverse to the working axis 116 of the apparatus (i.e., the + / - Y direction of the coordinate axes of the figure). In the present example, the printing assembly 150 includes a pair of actuators 160 coupled to the first printhead row 155 and the second printhead row 157 of printheads 156, respectively, such that both printhead rows 155, 157 are movable relative to one another and the support carriage 152 of the printing assembly 150. It will be appreciated that, in some embodiments, the actuation of the image processing apparatus 14 can be performed during a first pass of the printing assembly 150 to scan the build area 120 and map the plurality of pixels positioned thereon. In this example, the controlled system 10 can actuate the printheads 156 in at least one of the printhead rows 155, 157 prior to steps 402 and 404.

[0271] In this example, the plurality of ejection nozzles 158 included in each of the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 are repositioned from a default position to an actuated position that differs from the default position by at least some incremental distance (e.g., incremental distances “A” through “G” of FIGS. 17A-17G Thereby, during a second pass of the printing assembly 150 over the build area 120, at least one pixel positioned along the build area 120 will receive material from at least one ejection nozzle 158 of the plurality of ejection nozzles 158 that is different from the ejection nozzle 158 that previously deposited or attempted to deposit material to the pixel during the first pass. It will be appreciated that the lateral movement of the printheads in the first printhead row 155 and the second printhead row 157 from the default positions relative to one another and the previous positions of the printhead rows 155, 157 provides for enhanced ejection redundancy of the manufacturing process by increasing the reliability of the full resolution of each of the plurality of pixels on the build area 120 receiving adequate material deposition.

[0272] Referring back to FIG. 25When executed by the processor of the controlled system 10, the computer-readable executable instructions cause the method 400 to return to step 402, repeating the steps shown and described therein for a second pass. In particular, when executed by the processor of the controlled system 10, the computer-readable executable instructions transmit signals to the first actuator assembly 102 to translate the print assembly 150 from the translation position 253 to the home position 151 so that the printhead 154 moves over the build area 120 during the second pass. When executed by the processor of the controlled system 10, the computer-readable executable instructions transmit signals to the plurality of printheads 156 to release material from the first printhead row 155 and the second printhead row 157, respectively, thereby depositing additional material onto the plurality of pixels of the build area 120 as the printhead 154 moves over the build area 120 in the second pass. In this example, the printhead 154 thus moves over the build area 120 from the translation position 253 to the home position 151 as additional material is released from the printhead 154 during the second pass.

[0273] In other embodiments, the controlled system 10 transmits signals to the first actuator assembly 102 of the apparatus 100 to translate the print assembly 150 from the translation position 253 to the home position 151 prior to initiating the second pass so that, during the second pass, the printhead 154 again moves over the build area 120 from the home position 151 to the translation position 253. In this example, the printhead 154 moves over the build area 120 from the home position 151 to the translation position 253 as additional material is released from the printhead 154 during the second pass.

[0274] As described in greater detail above, in some embodiments, the controlled system 10 can actuate the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 relative to one another and the support carriage 152 in various ways during the first pass and / or the second pass. For example, such movement of the printheads 156 can be randomly generated by the controlled system 10 or predetermined based on calculated measurements of previous positions of the plurality of printheads 156 during previous passes of the print assembly 150. In either example, movement of the printhead rows 155, 157 of printheads 156 prior to each pass of the print assembly 150 provides enhanced material ejection redundancy of the manufacturing process by increasing the reliability of adequate material deposition from more than one ejection nozzle 158 being received on each of the plurality of pixels on the build area 120. The controlled system 10 then repeats the steps detailed above until the three-dimensional part to be printed by the apparatus 100 is complete and no additional material is to be deposited at step 406.

[0275] Although this example of exemplary method 400 depicts and describes that, prior to moving to translational position 253, the printing assembly 150 of device 100 is initially positioned in original position 151, and the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 are in actuated position ( FIG. 18B Previously, the layout was in the default position. FIG. 18A However, it should be understood that, without departing from the scope of this disclosure, in other embodiments, the printing assembly 150 may be initially positioned in the translational position 253, with the plurality of printheads 156 in the printhead rows 155, 157 arranged in the actuated position. Furthermore, it should be understood that the exemplary method 400 described and illustrated herein can be implemented by various other printing assemblies besides the printing assembly 150, such as, for example, the three-row printing assembly described above. It should be further understood that, in some embodiments, one or more steps of the method 400 described above may be adjusted, varied, and / or entirely omitted, including but not limited to the steps of: releasing material from the plurality of ejection nozzles 158 onto the plurality of pixels of the build area 120; determining whether the printing assembly 150 is in the translational position 253; stopping the release of material from the plurality of ejection nozzles 158; stopping the movement of the printing assembly 150, etc.

[0276] Now for reference FIGS. 19A-19B Together FIG. 26 Together with the flowchart, an exemplary method 500 is schematically depicted in which a plurality of printhead rows 155, 157 of a printing assembly 150 are actuated during the construction of an object in a manufacturing apparatus 100. More specifically, the movement of a plurality of printhead rows 155, 157 of a plurality of printheads 156 for depositing adhesive material 50 and / or other materials 114, 115 along a build area 120 is used to reduce the incidence of resolution defects on the printed object or part during image transmission processing due to a lack of jet redundancy. FIGS. 19A-19B and FIG. 26 The descriptions herein and the accompanying descriptions are not intended to limit the subject matter described herein or to represent an exact description of how material is deposited from the printing assembly 150, but are intended to provide a simple schematic overview to illustrate the general movement of the plurality of printhead rows 155, 157 of the printhead 156 of the printing assembly 150, thereby improving the jetting redundancy described herein.

[0277] refer to FIG. 19AAt step 502, the computer-readable executable instructions, when executed by the processor of the controlled system 10, transmit a signal to the first actuator assembly 102 to cause the print assembly 150 to move in a first stroke across the build area 120. In particular, the print assembly 150 translates across the rails 104 of the apparatus 100 and along the working axis 116, thereby moving the print head 154 over the build area 120 in the +X direction of the coordinate axes of the drawings. As the print head 154 of the print assembly 150 moves over the build area 120, the controlled system 10 sends signals to the plurality of print heads 156 in the first print head row 155 and the second print head row 157 to release material from the plurality of ejection nozzles 158. The material (e.g., the binder material 50, the first material 114, the second material 115, etc.) is delivered to the print head 154 and deposited onto the build area 120 by the plurality of ejection nozzles 158 of the plurality of print heads 156 in both the first print head row 155 and the second print head row 157.

[0278] In the present example, the plurality of print heads 156 in the first print head row 155 and the plurality of print heads 156 in the second print head row 157 deposit material along the build area 120. As such, at least some of the plurality of ejection nozzles 158 from the plurality of print heads 156 in the first print head row 155 and the second print head row 157 eject material over at least one pixel positioned along the build area 120. In this example, the plurality of print heads 156 in the first print head row 155 and the second print head row 157 are in a default position relative to one another as the print assembly 150 deposits material onto the build area 120 of the apparatus 100. As will be described in greater detail herein, in other embodiments, the plurality of print heads 156 in the first print head row 155 can deposit a different material than the plurality of print heads 156 in the second print head row 157 (see FIG. 27 ).

[0279] Still referring to FIG. 19A At step 504, as the material is ejected onto the build area 120, the computer-readable executable instructions executed by the processor cause the controlled system 10 to monitor the release of material from the plurality of ejection nozzles 158 of the plurality of print heads 156 from both the first print head row 155 and the second print head row 157. In particular, the release of material can be monitored by detecting and measuring the amount, volume, velocity, etc. of material ejected from the plurality of print heads 156. In embodiments, the apparatus 100 can include one or more sensors (not depicted) configured to detect the release of material from the plurality of print heads 156. In this example, the controlled system 10 measures the output of the print heads 156 and, in particular, monitors the material output from the plurality of ejection nozzles 158 for each print head 156 within the first print head row 155 and the second print head row 157, respectively.

[0280] The computer-readable executable instructions executed by the processor cause the control system 10 to determine whether the print assembly 150 has reached a translation position 253 in the + / - X direction at or past an edge of the build area 120 where material is to be deposited in the build area 120 by the print assembly 150 in the first pass. As the print assembly 150 translates along the working axis 116 of the apparatus 100 (i.e., the +X direction of the coordinate axis in the figure) toward the translation position 253, the control system 10 determines whether the print assembly 150 has reached the translation position 253, for example, by monitoring the relative position of the print assembly 150 along the guide rail 104.

[0281] With reference to FIG. 26 In response to determining that the print assembly 150 is not positioned at the translation position 253, the computer-readable executable instructions executed by the processor cause the control system 10 to transmit a signal to the first actuator assembly 102 to continue translating the print assembly 150 past the build area 120 at step 502. The control system 10 further transmits a signal to the printhead 154 to release material from the plurality of ejection nozzles 158 of the plurality of print heads 156 in the first print head row 155 and the second print head row 157 and monitors the output of the released material from the plurality of ejection nozzles 158 at step 504.

[0282] Alternatively, in response to determining that the print assembly 150 is positioned at the translation position 253, the control system 10 transmits a signal to the printhead 154 to terminate the release of material from the plurality of ejection nozzles 158 of the plurality of print heads 156. Additionally and / or concurrently, the instructions executed by the processor cause the control system 10 to transmit a signal to the first actuator assembly 102 to terminate movement of the print assembly 150 along the working axis 116 by refraining from actuation of the first actuator assembly 102. With the print assembly 150 positioned at the translation position 253, a plurality of pixels positioned along the build area 120 have received material thereon from at least the first print head row 155 or the second print head row 157 during the first pass of the print assembly 150 over the build area 120 in the +X direction of the coordinate axis.

[0283] Still with reference to FIG. 26At step 506, the computer-readable executable instructions, when executed by the processor of the controlled system 10, determine whether the output of the printheads 156 is equal to a predetermined threshold output. In some embodiments, the controlled system 10 can determine whether the output of a particular printhead row 155, 157 of the print heads 156 is equal to a predetermined threshold for the printhead row 155, 157. In other embodiments, the controlled system 10 can determine whether the output of each individual printhead 156 in each printhead row 155, 157 meets a predetermined output threshold. In further embodiments, the controlled system 10 can determine whether the output of each ejection nozzle 158 of each of a plurality of printheads 156 within a printhead row 155, 157 has discharged an equivalent of a predetermined threshold of material.

[0284] This determination by the controlled system 10 can be performed via a variety of devices and / or systems capable of detecting, monitoring, and / or measuring the output of material from a plurality of ejection nozzles 158. In the present example, the printing assembly 150 includes at least one sensor (e.g., a camera) for each of the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157, such that the plurality of sensors are configured to monitor the output of material from each of the plurality of ejection nozzles 158. At step 508, in response to the controlled system 10 determining that the output of material from the plurality of ejection nozzles 158 of each of the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 is equal to a predetermined threshold, the computer-readable executable instructions executed by the processor cause the controlled system 10 to determine whether additional layer material (e.g., adhesive) is to be deposited from the printing assembly 150.

[0285] Still referring to FIG. 26 At step 510, in response to determining at step 508 that no additional layer material (e.g., adhesive) is to be deposited, the controlled system 10 transmits a signal to the apparatus 100 to end the additive manufacturing process of the method 500. Alternatively, in response to determining at step 508 that additional layer material (e.g., adhesive) is to be deposited, the computer-readable executable instructions executed by the processor cause the controlled system 10 to return to step 502 to repeat the steps shown and described herein for a second pass.

[0286] Referring now to FIG. 19BIn step 512, in response to the control system 10 determining that the output of material from the plurality of ejection nozzles 158 of each of the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 is not equal to a predetermined threshold, the control system 10 actuates at least one of the plurality of printheads 156 in the first printhead row 155 or the second printhead row 157. Specifically, by identifying that the material output from the plurality of ejection nozzles 158 does not meet the predetermined output threshold, the control system 10 determines that there is insufficient material released from the printing assembly 150 onto the plurality of pixels along the build region 120, such that printing defects and / or errors may have occurred during previous strokes of the printing assembly 150.

[0287] As discussed in detail above, such defects and / or errors can be caused by misfires and / or blockages in one or more of the multiple ejection nozzles 158 of the multiple printheads 156. In this example, moving the first printhead row 155 and / or the second printhead row 157 of the multiple printheads 156 relative to each other and relative to the support bracket 152 realigns the multiple ejection nozzles 158 with the multiple pixels. In this example, the multiple printheads 156 are actuated only in response to the control system 10 determining that a possible error has occurred, such that the multiple printheads 156 in the printhead rows 155, 157 are additionally kept in a fixed arrangement relative to each other. Thus, each pixel along the build area 120 can receive material from the nozzle 158 aligned with the pixel during the first stroke of the printing assembly 150, and from at least one different nozzle 158 during the second stroke.

[0288] Still referencing FIG. 19B By realigning multiple ejector nozzles 158 in response to the movement of multiple printheads 156 in the first printhead row 155 and the second printhead row 157 from, for example, a default position to an actuated position, the ejection resolution of the device 100 can be enhanced. In other words, the likelihood of ejector nozzles 158 not being adequately aligned with a particular pixel during subsequent strokes of the printing assembly 150 on the build region 120 can be reduced. Computer-readable and executable instructions executed by the processor cause the control system 10 to return to step 502, repeating the steps shown and described herein for the second stroke.

[0289] Although this example of exemplary method 500 depicts and describes that, prior to moving to translational position 253, the printing assembly 150 of device 100 is initially positioned in original position 151, and the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 are in actuated position ( FIGS. 2-11 Previously, it was arranged in the default position. FIG. 4However, it should be understood that, without departing from the scope of this disclosure, in other embodiments, the printing assembly 150 may be initially positioned at translational position 253, with the plurality of printheads 156 in the printhead rows 155, 157 arranged in an actuated position. Furthermore, it should be understood that the exemplary method 500 described and illustrated herein can be implemented by various other printing assemblies besides the printing assembly 150, such as, for example, the three-row printing assembly described above. It should be further understood that, in some embodiments, one or more steps of the method 500 described above may be adjusted, varied, and / or entirely omitted, including but not limited to the steps of: releasing material from the plurality of jet nozzles 158 onto the plurality of pixels of the build area 120, determining whether the printing assembly 150 is in translational position 253, stopping the release of material from the plurality of jet nozzles 158, stopping the movement of the printing assembly 150, etc.

[0290] Now for reference FIGS. 20A-20B Together FIG. 27 Together with the flowchart, an exemplary method 600 is schematically depicted in which a plurality of printhead rows 155, 157 of a printing assembly 150 are actuated during the construction of an object in a manufacturing apparatus 100. More specifically, the movement of a plurality of printhead rows 155, 157 of a plurality of printheads 156 for depositing adhesive material 50 and / or other materials 114, 115 along a build area 120 is used to reduce the incidence of resolution defects on the printed object or part during image transmission processing. FIGS. 20A-20B and FIG. 27 The descriptions herein and the accompanying descriptions are not intended to limit the subject matter described herein or to represent an exact description of how material is deposited from the printing assembly 150, but are intended to provide a simple schematic overview to illustrate the general movement of the plurality of printhead rows 155, 157 of the printhead 156 of the printing assembly 150 to eject the various materials described herein.

[0291] refer to FIG. 20A In step 602, when executed by the processor of the controlled system 10, computer-readable and executable instructions transmit signals to the first actuator assembly 102 to cause the printing assembly 150 to translate across the build area 120 in the first stroke. Specifically, the printing assembly 150 translates across the guide rail 104 of the device 100 and along the working axis 116, thereby moving the print head 154 in the build area 120 in the +X direction of the coordinate axis in the figure. In this example, a plurality of print heads 156 in the first print head row 155 are connected via the first conduit 111 (see [reference]). FIG. 1B The first printhead 156 is communicatively connected to the first fluid reservoir 110, enabling a plurality of printheads 156 in the first printhead row 155 to operate to deposit a first material 114 along the build region 120. Further, a plurality of printheads 156 in the second printhead row 157 are connected via a second conduit 113 (see...). FIG. 1BThe first fluid head 155 is communicatively connected to the second fluid reservoir 112, enabling the plurality of printheads 156 in the second printhead row 157 to operate to deposit a second material 115 along the build region 120. It should be understood that in other embodiments, the printheads 156 in the first printhead row 155 and the second printhead row 157 may be connected to the same reservoir, and / or the materials stored in the first fluid reservoir 110 and the second fluid reservoir 112 may be the same.

[0292] In step 604, when executed by the processor of the controlled system 10, computer-readable and executable instructions transmit signals to the plurality of printheads 156 in the first printhead row 155 to release first material 114 from the first fluid reservoir 110 through the plurality of jet nozzles 158 defining the printheads 156 of the first printhead row 155. As the printing assembly 150 moves across the build region 120, the first material 114 is transferred to the printheads 156 and deposited onto the build region 120 through the plurality of jet nozzles 158. In step 606, the controlled system 10 transmits signals to the plurality of printheads 156 in the second printhead row 157 to release second material 115 from the second fluid reservoir 112 through the plurality of jet nozzles 158 defining the printheads 156 of the second printhead row 157. As the printing assembly 150 moves across the build region 120, the second material 115 is transferred to the printheads 156 and deposited onto the build region 120 through the plurality of jet nozzles 158.

[0293] Thus, each of the plurality of ejection nozzles 158 from the plurality of printheads 156 of the first printhead row 155 and the second printhead row 157 deposits at least one of material 114, 115 onto at least one pixel positioned along the build region 120. In this example, as the printing assembly 150 deposits the first material 114 and the second material 115 onto the build region 120 of the device 100, the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 are in a default position relative to each other (see [link to documentation]). FIG. 4 ).

[0294] Now for reference FIG. 20B When executed by the processor of the controlled system 10, computer-readable and executable instructions determine whether the printing assembly 150 has reached a translational position 253 in the + / -X direction, which is at or past the edge of the build region 120, where material will be deposited in the build region 120 during the first stroke. As the printing assembly 150 translates towards the translational position 253 along the working axis 116 of the device 100 (i.e., the +X direction of the coordinate axis in the figure), the controlled system 10 determines whether the printing assembly 150 has reached the translational position 253, for example, by monitoring the relative position of the printing assembly 150 along the guide rail 104.

[0295] At step 602, in response to determining that the print assembly 150 is not positioned at the translation position 253, the control system 10 transmits a signal to the first actuator assembly 102 to continue translating the print assembly 150 across the build area 120; release the first material 114 from the plurality of print heads 156 in the first print head row 155; and release the second material 115 from the plurality of print heads 156 in the second print head row 157.

[0296] Alternatively, in response to determining that the print assembly 150 is positioned at the translation position 253, the computer readable executable instructions, when executed by the processor of the control system 10, transmit a signal to the print heads 154 to terminate release of the first material 114 and the second material 115 from the plurality of print heads 156 in the first print head row 155 and the second print head row 157, respectively. Additionally and / or concurrently, the control system 10 transmits a signal to the first actuator assembly 102 to terminate movement of the print assembly 150 along the working axis 116.

[0297] Still referring to FIG. 20B With the print assembly 150 positioned at the translation position 253, based on the relative positions of the pixels, during the first pass of the print assembly 150, a plurality of pixels positioned along the build area 120 have received thereon at least one of the first material 114 and the second material 115. As such, due to the first print head row 155 and the second print head row 157 of the print heads 156 remaining in a relatively fixed position during the first pass of the print assembly 150 over the build area 120, based on the alignment of the pixels with the ejection nozzles 158 of the print heads 156 in the first print head row 155 or the second print head row 157, each of the plurality of pixels along the build area 120 can receive only one of the first material 114 or the second material 115.

[0298] Referring to FIG. 27 At step 608, due to the arresting of movement of the print assembly 150 and the termination of release of material 114, 115 from the print head rows 155, 157 of the print heads 156, the computer readable executable instructions executed by the processor of the control system 10 cause the apparatus 100 to determine whether additional layer material (e.g., adhesive) is to be deposited by the print assembly 150. This determination by the control system 10 can be performed via the various means and / or systems described in detail above. At step 610, in response to determining at step 608 that no additional layer material is required to be deposited, the control system 10 transmits a signal to the apparatus 100 to end the additive manufacturing process of the method 600.

[0299] Referring back to FIG. 20BAt step 612, in response to determining at step 608 that additional adhesive or other material needs to be deposited by the print assembly 150, the control system 10 transmits a signal to at least one actuator 160 coupled to the plurality of print heads 156 in the first print head row 155. In this example, the plurality of ejection nozzles 158 of the plurality of print heads 156 defining the first print head row 155 are moved relative to the plurality of ejection nozzles 158 of the plurality of print heads 156 defining the second print head row 157. At step 614, the control system 10 transmits a signal to at least one actuator 160 coupled to the plurality of print heads 156 in the second print head row 157. In this example, the plurality of ejection nozzles 158 of the plurality of print heads 156 defining the second print head row 157 are moved relative to the plurality of ejection nozzles 158 of the plurality of print heads 156 defining the first print head row 155. It will be appreciated that in other embodiments, the plurality of print heads 156 in the second print head row 157 do not include an actuator coupled thereto, such that step 614 is omitted.

[0300] Referring back to FIG. 27 When executed by the processor of the control system 10, the computer-readable executable instructions cause the method 600 to return to step 602 and repeat the steps shown and described herein for a second pass. In particular, when executed by the processor of the control system 10, the computer-readable executable instructions transmit a signal to the first actuator assembly 102 to cause the print assembly 150 to translate across the build area 120 in the second pass. In particular, the print assembly 150 translates across the rails 104 of the apparatus 100 and along the working axis 116, thereby moving the print head 154 over the build area 120 in the -X direction of the coordinate axes of the drawings. When executed by the processor of the control system 10, the computer-readable executable instructions transmit a signal to the plurality of print heads 156 in the first print head row 155 to release the first material 114 through the plurality of ejection nozzles 158 of the print heads 156 defining the first print head row 155. The control system 10 transmits a signal to the plurality of print heads 156 in the second print head row 157 to release the second material 115 through the plurality of ejection nozzles 158 of the print heads 156 defining the second print head row 157.

[0301] In this way, as the print assembly 150 moves across the build area 120 in the second pass, the first material 114 is transferred from the first fluid reservoir 110 to the print heads 156 in the first print head row 155 and deposited onto the build area 120 through the plurality of ejection nozzles 158. As the print assembly 150 moves across the build area 120 in the second pass, the second material 115 is transferred from the second fluid reservoir 112 to the print heads 156 in the second print head row 157 and deposited onto the build area 120 through the plurality of ejection nozzles 158. As FIG. 20BAs seen in FIG. 6, during the second pass, the first material 114 can be deposited on pixels of the build area 120 that received the second material 115 during the first pass. Additionally, during the second pass, the second material 115 can be deposited on pixels of the build area 120 that received the first material 114 during the first pass. In this example, the apparatus 100 is operable to deposit several materials 114, 115 on the build area 120, particularly, on similar pixels along the build area 120, such that one or more pixels can receive several materials 114, 115 thereon. The control system 10 then repeats the steps described in detail above until the three-dimensional part to be printed by the apparatus 100 is complete and no additional layer material is to be deposited at step 608.

[0302] While the present example of the example method 600 depicts and describes the print assembly 150 of the apparatus 100 initially positioned in the home position 151 prior to moving to the translation position 253, and the plurality of print heads 156 in the first print head row 155 and / or the second print head row 157 arranged in the default position prior to moving to the plurality of actuated positions, it should be understood that in other embodiments, the print assembly 150 can initially be positioned in the translation position 253 with the plurality of print heads 156 in the print head rows 155, 157 arranged in a position other than the default position without departing from the scope of the present disclosure. Additionally, it should be understood that the example method 600 described and illustrated herein can be performed by various other print assemblies other than the print assembly 150, such as, for example, the three-row print assembly described above. It should be further understood that in some embodiments, one or more steps of the method 600 described above can be adjusted, varied, and / or omitted entirely, including but not limited to the steps of releasing material from the plurality of ejection nozzles 158 onto the plurality of pixels of the build area 120, determining whether the print assembly 150 is in the translation position 253, inhibiting the release of material from the plurality of ejection nozzles 158, inhibiting movement of the print assembly 150, and the like.

[0303] Referring now to the flowchart of FIG. 7, FIG. 28 an example method 700 of actuating the plurality of print head rows 155, 157 of the print assembly 150 when building an object with the apparatus 100 is schematically depicted. More particularly, movement of the plurality of print head rows 155, 157 of the plurality of print heads 156 used to deposit the binder material 50 and / or other materials 114, 115 along the build area 120 serves to reduce the incidence of resolution defects on the object or part being printed during the image transfer process due to a lack of ejection redundancy. FIG. 28The depiction and the following description accompanying the drawings are intended to provide a simple, schematic overview of the general movement of the plurality of print head rows 155, 157 of the print head 156 of the printing assembly 150 to improve the ejection redundancy described herein, and are not intended to limit the subject matter described herein or represent an exact description of how material is deposited from the printing assembly 150.

[0304] At step 702, the computer-readable executable instructions, when executed by the processor of the control system 10, transmit a signal to the first actuator assembly 102 to cause the printing assembly 150 to translate across the build area 120 in a first pass. In particular, the printing assembly 150 translates across the rails 104 of the apparatus 100 and along the working axis 116, thereby moving the print head 154 over the build area 120 in the +X direction of the coordinate axes of the accompanying drawings. The computer-readable executable instructions, when executed by the processor of the control system 10, further transmit a signal to the plurality of print heads 156 in the first print head row 155 and the second print head row 157 to release material from the plurality of ejection nozzles 158 of each print head as the print head 154 moves over the build area 120. Material (e.g., the binder material 50, the first material 114, the second material 115, etc.) is transported to the print head 154 and deposited onto the build area 120 by the plurality of ejection nozzles 158 of the plurality of print heads 156 in both the first print head row 155 and the second print head row 157.

[0305] In the present example, the plurality of print heads 156 in the first print head row 155 and the plurality of print heads 156 in the second print head row 157 deposit the same material (e.g., the binder material 50, the first material 114, the second material 115, etc.) along the build area 120. As such, each of the plurality of ejection nozzles 158 from the plurality of print heads 156 in the first print head row 155 and the second print head row 157 ejects material over at least one pixel positioned along the build area 120. In this example, the plurality of print heads 156 in the first print head row 155 and the second print head row 157 are in a default position (see FIG. 4 ) relative to one another when the printing assembly 150 begins depositing material onto the build area 120 of the apparatus 100.

[0306] Still referring to FIG. 28At step 704, the computer-readable executable instructions, when executed by the processor of the controlled system 10, transmit signals to at least one actuator 160 of the printhead 154 to move at least one of the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 relative to one another. In other words, as the print assembly 150 moves across the build area 120 at step 702, and as the plurality of printheads 156 release material onto the pixels of the build area 120 through the plurality of ejection nozzles 158, the at least one actuator 160 coupled to at least one of the first printhead row 155 and / or the second printhead row 157 actuates in synchrony. The first printhead row 155 and / or the second printhead row 157 translates in a plurality of directions transverse to the working axis 116 of the apparatus (i.e., the + / - Y direction of the coordinate axes in the figure), whereby the plurality of ejection nozzles 158 of the printheads 156 located in the respective printhead row 155, 157 are moved from a default position (see FIG. 4 ) to a plurality of positions.

[0307] It will be appreciated that the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 are continuously actuated (i.e., translated) to a plurality of positions at step 704 as the print assembly 150 moves across the build area 120 and releases material onto the plurality of pixels of the build area 120. Thus, the first printhead row 155 and / or the second printhead row 157 are positioned relative to one another in a plurality of arrangements during the material deposition process at step 704. In the present example, the print assembly 150 includes an actuator 160 coupled to each of the first printhead row 155 and the second printhead row 157 of printheads 156, respectively, such that both printhead rows 155, 157 are movable relative to one another and relative to the support carriage 152 of the print assembly 150. In this example, the plurality of ejection nozzles 158 of each of the plurality of printheads 156 defining the first printhead row 155 and the second printhead row 157 are continuously repositioned from a default position to an actuated position that differs from the default position by at least some incremental distance (e.g., the incremental distances A through G of FIGS. 17A-17G Thus, the plurality of pixels located along the build area 120 will receive material thereon from a number of ejection nozzles 158 during the first pass of the print assembly 150 over the build area 120.

[0308] It should be appreciated that in some embodiments, the movement of the first printhead row 155 and the second printhead row 157 relative to each other and relative to previous positions of the printhead rows 155, 157 during a current pass of the print assembly 150 over the build area 120 can be arbitrary. In this example, the computer readable executable instructions, when executed by the processor of the control system 10, communicate signals to the actuators 160 to move the first printhead row 155 and the second printhead row 157 of the plurality of printheads 156 relative to each other to a plurality of positions that are randomly generated. In this embodiment, by continually repositioning the plurality of printheads 156 in each printhead row 155, 157 in an uncalculated manner, spray redundancy is provided through the print assembly 150 such that a plurality of pixels along the build area 120 are effectively aligned with a plurality of spray nozzles 158 during a current pass of the print assembly 150.

[0309] In other embodiments, the movement of the first printhead row 155 and the second printhead row 157 relative to each other and relative to previous positions of the printhead rows 155, 157 during a current pass of the print assembly 150 over the build area 120 can be predetermined by the control system 10. In this example, the computer readable executable instructions, when executed by the processor of the control system 10, communicate signals to the actuators 160 to move the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 to a plurality of measured positions that vary relative to previous positions of the printhead rows 155, 157 during the current pass. In this embodiment, by continually repositioning the plurality of printheads 156 in each printhead row 155, 157 in a calculated manner, spray redundancy is provided through the print assembly 150 such that a plurality of pixels along the build area 120 are effectively aligned with a plurality of spray nozzles 158 during a current pass of the print assembly 150.

[0310] The control system 10 can determine the calculated positions of the plurality of printheads 156 in the printhead rows 155, 157 through various systems, such as, for example, camera images, sensor outputs, calibration patterns, and the like. In either example, the continual movement of the first printhead row 155 and the second printhead row 157 of printheads 156 during a first pass of the print assembly 150 provides enhanced material spray redundancy of the manufacturing process by increasing the reliability of adequate material deposition from more than one spray nozzle 158 being received on each of the plurality of pixels on the build area 120.

[0311] Still referring to FIG. 28When executed by the processor of the control system 10, the computer-readable executable instructions determine whether the print assembly 150 has reached the translation position 253 (see FIG. 1). As the print assembly 150 translates along the work axis 116 of the device 100 (i.e., the +X direction of the coordinate axis of the figure) past the translation position 253, the control system 10 determines whether the print assembly 150 has reached the translation position 253, for example, by monitoring the relative position of the print assembly 150 along the guide rail 104. In response to determining that the print assembly 150 is not positioned at the translation position 253, when executed by the processor of the control system 10, the computer-readable executable instructions communicate a signal to the first actuator assembly 102 to continue translating the print assembly 150 past the build area 120 at step 502; release material from the plurality of print heads 156 in the first print head row 155 and the second print head row 157; and, at step 704, cause the first print head row 155 and the second print head row 157 to move to a plurality of positions.

[0312] Alternatively, in response to determining that the print assembly 150 is positioned at the translation position 253, when executed by the processor of the control system 10, the computer-readable executable instructions communicate a signal to the print heads 154 to terminate the release of material from the plurality of ejection nozzles 158 of the plurality of print heads 156. Additionally and / or synchronously, when executed by the processor of the control system 10, the computer-readable executable instructions communicate a signal to the first actuator assembly 102 to terminate movement of the print assembly 150 along the work axis 116. With the print assembly 150 positioned at the translation position 253, during a first pass of the print assembly 150 over the build area 120, a plurality of pixels positioned along the build area 120 have received material from more than one ejection nozzle 158 due to the continued movement of the first print head row 155 and the second print head row 157 during the first pass.

[0313] Still referring to FIG. 28When executed by the processor of the controlled system 10, the computer-readable executable instructions transmit a signal to each of the actuators 160 coupled to the first printhead row 155 of printheads 156 and the second printhead row 157 of printheads 156, respectively, to terminate movement of the printhead rows 155, 157 relative to one another. At step 706, with movement of the printing assembly 150 and actuation of the printhead rows 155, 157 of printheads 156 arrested, the computer-readable executable instructions executed by the processor of the controlled system 10 cause the apparatus 100 to determine whether additional layer material (e.g., adhesive) is to be printed. This determination by the controlled system 10 can be performed via the various means and / or systems described in detail above. In response to a determination at step 706 that no additional layer material is to be deposited by the apparatus 100, when executed by the processor of the controlled system 10, the computer-readable executable instructions transmit a signal to the apparatus 100 to end the manufacturing process of the method 700 at step 708.

[0314] Alternatively, in response to a determination at step 706 that additional layer material is to be deposited by the apparatus 100, when executed by the processor of the controlled system 10, the computer-readable executable instructions cause the method 700 to return to step 702, repeating the steps shown and described herein for a second pass. In this example, the instructions by the processor of the controlled system 10 cause the apparatus 100 to repeat the steps described in detail above until the three-dimensional model to be printed by the apparatus 100 is complete and no additional layer material is to be printed at step 706.

[0315] While the present example of the example method 700 depicts and describes the printing assembly 150 of the apparatus 100 initially positioned at the home position 151 prior to movement to the translation position 253, and the plurality of printheads 156 in the first printhead row 155 and / or the second printhead row 157 arranged in the default position prior to movement to the plurality of actuated positions, it should be appreciated that in other embodiments, the printing assembly 150 can be initially positioned at the translation position 253 with the plurality of printheads 156 in the printhead rows 155, 157 arranged in a position other than the default position without departing from the scope of the present disclosure. Additionally, it should be appreciated that the example method 700 described and shown herein can be performed by various other printing assemblies other than the printing assembly 150, such as, for example, the three-row printing assembly described above. It should be further appreciated that in some embodiments, one or more steps of the method 700 described above can be adjusted, varied, and / or omitted entirely, including but not limited to the following steps: releasing material from the plurality of ejection nozzles 158 onto the plurality of pixels of the build area 120, determining whether the printing assembly 150 is at the translation position 253, arresting the release of material from the plurality of ejection nozzles 158, arresting movement of the printing assembly 150, and the like.

[0316] Referring now toFIG. 29 FIG. 8 is a flow diagram schematically depicting an example method 800 of actuating a number of printhead rows 155, 157 of a print assembly 150 when building an object with a manufacturing apparatus 100. More specifically, movement of a number of printhead rows 155, 157 of a plurality of printheads 156 used to deposit a binding agent material 50 and / or other materials 114, 115 along a build area 120 serves to reduce the incidence of resolution defects on a printed object or part during an image transfer process due to a lack of jet redundancy. FIG. 29 The depiction of FIG. 8 and the following description that follows is not meant to limit the subject matter described herein or represent an exact description of how material is deposited from a print assembly 150, but rather is meant to provide a simple schematic overview to illustrate the general movement of a number of printhead rows 155, 157 of printheads 156 of a print assembly 150 to improve the jet redundancy described herein.

[0317] At step 802, the computer readable executable instructions, when executed by a processor of a control system 10, receive an input of a programmable build size for the print assembly 150 to employ prior to initiating a material deposition process. As briefly described above, the print assembly 150 is configured to dynamically adjust an effective build size of the print head 154 in response to moving at least one of the plurality of printheads 156 of the first printhead row 155 and / or the second printhead row 157. It should be appreciated that the build size of the print head 154 corresponds to a lateral width (on the + / -Y axis of the coordinate axis in the figure) of a jetting range and / or field of view of the plurality of printheads 156 disposed therein. By moving the plurality of printheads 156 of the first printhead row 155 and the second printhead row 157 relative to one another and the support carriage 152 of the print assembly 150 in a number of row arrangements (on the + / -Y axis of the coordinate axis in the figure), the jetting range of the print head 154 can be dynamically adjusted (e.g., increased or decreased).

[0318] For example, by generally aligning the plurality of printheads 156 of the first printhead row 155 and the second printhead row 157 with one another on the + / -Y axis of the coordinate axis in the figure, the build size and / or width of the print head 154 can be relatively minimal such that the overall jetting range of the print head 154 (on the + / -Y axis of the coordinate axis in the figure) is minimized. In other words, the plurality of printheads 156 of the first printhead row 155 and the second printhead row 157 are translated on the + / -Y axis of the coordinate axis in the figure to generally overlap one another on the + / -X axis of the coordinate axis in the figure. In response to actuating the plurality of printheads 156 of the first printhead row 155 and the second printhead row 157 to form an overlap of the plurality of jetting nozzles 158 (on the + / -Y axis of the coordinate axis in the figure), an example of the print head 154 of the print assembly 150 including a relatively minimal build size is shown in FIG. 8. FIGS. 17A-17C For example, by generally aligning the plurality of printheads 156 of the first printhead row 155 and the second printhead row 157 with one another on the + / -Y axis of the coordinate axis in the figure, the build size and / or width of the print head 154 can be relatively minimal such that the overall jetting range of the print head 154 (on the + / -Y axis of the coordinate axis in the figure) is minimized. In other words, the plurality of printheads 156 of the first printhead row 155 and the second printhead row 157 are translated on the + / -Y axis of the coordinate axis in the figure to generally overlap one another on the + / -X axis of the coordinate axis in the figure. In response to actuating the plurality of printheads 156 of the first printhead row 155 and the second printhead row 157 to form an overlap of the plurality of jetting nozzles 158 (on the + / -Y axis of the coordinate axis in the figure), an example of the print head 154 of the print assembly 150 including a relatively minimal build size is shown in FIG. 8.

[0319] By way of further example, by offsetting the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 from one another generally on the + / -Y-axis of the coordinate axis in the figure, the build size and / or width of the print head 154 can be relatively maximized such that the overall jetting range of the print head 154 (on the + / -Y-axis of the coordinate axis in the figure) is maximized. In other words, the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 are translated on the + / -Y-axis of the coordinate axis in the figure to be offset from one another generally on the + / -X-axis of the coordinate axis in the figure. Responsive to actuating the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 to extend the plurality of jetting nozzles 158 laterally (on the + / -Y-axis of the coordinate axis in the figure), an example of the print head 154 of the printing assembly 150 including a relatively maximized build size is illustrated in FIGS. 17D-17G .

[0320] Still referring to FIG. 29 , at step 804, the computer-readable executable instructions, when executed by the processor of the control system 10, actuate the first printhead row 155 and / or the second printhead row 157 of the plurality of printheads 156 in accordance with the build size input at step 802. It will be appreciated that the build size input can be arbitrary such that the effective print width of the printing assembly 150 is randomly generated; it can be pre-calculated by the control system of the apparatus 100 such that the effective print width of the printing assembly 150 is pre-defined; and / or it can be manually identified by an operator of the apparatus 100. At step 806, the computer-readable executable instructions, when executed by the processor of the control system 10, communicate a signal to the first actuator assembly 102 to translate the printing assembly 150 in a first pass over the build area 120. In particular, the printing assembly 150 translates over the rail 104 of the apparatus 100 and along the work axis 116, thereby moving the print head 154 over the build area 120 in the +X direction of the coordinate axis of the figure. The computer-readable executable instructions, when executed by the processor of the control system 10, further communicate a signal to the plurality of printheads 156 in the first printhead row 155 and the second printhead row 157 to release material from the plurality of jetting nozzles 158 of each printhead as the print head 154 is moved over the build area 120. The material (e.g., the binder material 50, the first material 114, the second material 115, etc.) is transported to the print head 154 and deposited onto the build area 120 by the plurality of jetting nozzles 158 of the plurality of printheads 156 in both the first printhead row 155 and the second printhead row 157.

[0321] In the present example, the plurality of print heads 156 of the first print head row 155 and the plurality of print heads 156 of the second print head row 157 deposit the same material (e.g., the binder material 50, the first material 114, the second material 115, etc.) along the build area 120. As such, each of the plurality of ejection nozzles 158 from the plurality of print heads 156 in the first print head row 155 and the second print head row 157 ejects material on at least one pixel positioned along the build area 120. In this example, upon the printing assembly 150 beginning to deposit material onto the build area 120 of the device 100, the plurality of print heads 156 in the first print head row 155 and the second print head row 157 are in an actuated position relative to one another in accordance with the input build dimensions of step 802.

[0322] Still referring to FIG. 29 When executed by the processor of the control system 10, the computer-readable executable instructions determine whether the printing assembly 150 has reached a translation position 253 in the + / - X direction at or past an edge of the build area 120 where material is to be deposited in the build area 120 by the printing assembly 150 in a first pass. As the printing assembly 150 translates along the working axis 116 of the device 100 (i.e., the +X direction of the coordinate axis of the figure) toward the translation position 253, the control system 10 determines whether the printing assembly 150 has reached the translation position 253, for example, by monitoring the relative position of the printing assembly 150 along the guide rail 104. In response to determining that the printing assembly 150 is not positioned at the translation position 253, the control system 10 communicates a signal to the first actuator assembly 102 to continue translating the printing assembly 150 past the build area 120 at step 802. The control system 10 further communicates a signal to the print head 154 to release material from the plurality of ejection nozzles 158 of the plurality of print heads 156 in the first print head row 155 and the second print head row 157.

[0323] Alternatively, in response to determining that the printing assembly 150 is positioned at the translation position 253, the computer-readable executable instructions, when executed by the processor of the control system 10, communicate a signal to the print head 154 to terminate the release of material from the plurality of ejection nozzles 158 of the plurality of print heads 156 in the first print head row 155 and the second print head row 157. Additionally and / or concurrently, the control system 10 communicates a signal to the first actuator assembly 102 to terminate movement of the printing assembly 150 along the working axis 116 by arresting actuation of the first actuator assembly 102. With the printing assembly 150 positioned at the translation position 253, during the first pass of the printing assembly 150 over the build area 120 in the +X direction of the coordinate axis, a plurality of pixels positioned along the build area 120 have received material thereon from at least the first print head row 155 or the second print head row 157.

[0324] Still referring to FIG. 29 At step 808, the control system 10 determines whether an additional layer of material (e.g., adhesive) is to be deposited from the print assembly 150. This determination by the control system 10 can be performed via the various means and / or systems described in detail above. In response to determining at step 808 that no additional layer of material (e.g., adhesive) is to be deposited from the print assembly 150, the control system 10 transmits a signal to the apparatus 100 to end the manufacturing process of the method 800. Alternatively, in response to determining at step 808 that an additional layer of material (e.g., adhesive) is to be deposited from the print assembly 150, at step 812, the computer-readable executable instructions executed by the processor of the control system 10 verify whether an equivalent build size is to be employed by the apparatus 100 for the print assembly 150 for a second pass of the print assembly 150 over the build area 120.

[0325] In response to determining at step 812 that a different build size is to be effectively employed by the print assembly 150, the instructions executed by the processor of the control system 10 cause the method 800 to return to step 802, repeating the steps shown and described herein for a second pass to determine a new effective build size for the print assembly 150. Alternatively, in response to determining at step 812 that an equivalent build size is to be effectively employed by the print assembly 150, the instructions executed by the processor of the control system 10 cause the method 800 to return to step 806, repeating the steps shown and described herein. In either instance, the instructions cause the apparatus 100 to repeat the steps described in detail above until the three-dimensional model to be printed by the apparatus 100 is complete or no additional layer of material is to be deposited at step 808.

[0326] While the present example of the example method 800 depicts and describes the print assembly 150 of the apparatus 100 initially being positioned in the home position 151 prior to moving to the translation position 253, and the plurality of print heads 156 of the first print head row 155 and / or the second print head row 157 being arranged to define the selected build size prior to the print assembly 150 moving over the build area 120, it should be appreciated that in other embodiments, the print assembly 150 can initially be positioned in the translation position 253 during the first pass, and the build size of the print assembly 150 is employed during and / or after the print assembly 150 moves over the build area 120, without departing from the scope of the present disclosure. Additionally, the plurality of print heads 156 of the print head rows 155, 157 can be arranged in the manner described above FIGS. 17A-17GMultiple other locations besides the positions shown and described herein. Furthermore, it should be understood that the exemplary method 800 described and illustrated herein can be implemented by various other printing components besides printing assembly 150, such as, for example, the three-row printing assembly described above. It should be further understood that in some embodiments, one or more steps of the method 800 described above may be adjusted, varied, and / or entirely omitted, including but not limited to the steps of: releasing material from multiple jet nozzles 158 onto multiple pixels of the build area 120, determining whether printing assembly 150 is at translational position 253, stopping the release of material from the multiple jet nozzles 158, stopping the movement of printing assembly 150, etc.

[0327] Now for reference FIG. 30 The flowchart depicts the use of reference FIGS. 21A-21E An exemplary method 900 for transposing the printing assembly 150 is described and depicted. More specifically, method 900 can be implemented via a control system 10 (e.g., an electronic control unit) of the device 100 depicted and described herein. It should be understood that, although FIGS. 24-32 Various methods are described and illustrated, but each of these methods and steps can be combined to form the logic and operation performed by the device 100 described herein.

[0328] refer to FIG. 30 Specifically, in block 902, the electronic control unit can receive construction instructions for constructing components. These construction instructions can be implemented by the computing device 15 (which implements the logic). FIG. 1 B This generates, for example, slicing engines, which define how the device can operate and what materials to use to construct special parts based on the input model or drawing.

[0329] The slicing engine can define multiple pixel and / or subpixel centers. Once the layers, pixels, and / or subpixel centers are defined, the slicing engine can begin determining the amount of adhesive deposited within each pixel of each layer. The predetermined amount of adhesive and the adhesive defining the layers receive the pixel combination of the surface to define a design deposition pattern for the layers of the part to be constructed. Construction instructions can include deposition patterns (e.g., 125, 126, or 127, respectively). FIG. 21C through FIG. 21E The deposition pattern defines the sites and amounts of binder to be deposited on the multilayer powder over the build area 120. The build instructions further include predefined motion controls for the first actuator assembly 102 and the second actuator assembly 103.

[0330] At block 904, the electronic control unit of the apparatus can actuate the printhead position control assembly (e.g., the first actuator assembly 102, the second actuator assembly 103, and other components) in accordance with the received build instructions. For example, the electronic control unit transmits one or more control signals that cause the first actuator assembly 102 and / or the second actuator assembly 103 to perform the movement defined by the build instructions. As described above, the actuators can include, but are not limited to, a worm drive actuator, a ball screw actuator, a pneumatic piston, a hydraulic piston, an electromechanical linear actuator, and the like. As such, the control signals from the electronic control unit can cause a motor associated with the worm drive actuator or the ball screw actuator to be energized for a period of time or until a number of revolutions are completed to cause the predetermined motion defined by the build instructions. In some examples, the first actuator assembly 102 and / or the second actuator assembly 103 can include a position sensor (e.g., 102a and / or 103a) that provides position information to the electronic control unit in a feedback control signal so that the electronic control unit can track the position of the print assembly 150 in response to the provided control signals. In some examples, the electronic control unit can adjust the control signals provided to the first actuator assembly 102 and / or the second actuator assembly 103 based on the position information provided by the position sensor (e.g., 102a and / or 103a). In embodiments, the position sensor (e.g., 102a and / or 103a) can be an encoder, an ultrasonic sensor, an optical-based sensor, a magnetic force sensor, or the like embedded or coupled to the first actuator assembly 102 and / or the second actuator assembly 103.

[0331] At block 906, the electronic control unit causes the print assembly 150, which includes at least one printhead 154, to traverse the build area 120 in a first pass trajectory in a first direction along the longitudinal axis. Additionally, the electronic control unit causes selected ejection nozzles of the plurality of ejection nozzles 158 to dispense one or more drops of a binding agent or other material onto the build area 120. The electronic control unit is communicatively coupled to one or more of the plurality of print heads 156 so that control signals generated by the electronic control unit cause the ejection nozzles associated with the printhead 154 to dispense the binding agent or other material in a predefined amount at a predefined bit location as defined by a deposition pattern (e.g., 125, FIG. 21C ) for a layer of powder being built as the print assembly 150 traverses the build area 120. Referring briefly back to FIG. 21C , the first pass of the print assembly 150 can deposit the binding agent in the locations and amounts depicted by the illustrative representation of the deposition pattern 125. During the first pass, the ejection nozzles 158 (e.g., depicted in FIG. 21A ) are aligned with the first pass trajectory depicted with hash marks, and deposit the binding agent in the amounts indicated by the values within each sub-pixel block along the first pass trajectory.

[0332] At block 908, once the pass of the build area by the print assembly 150 is complete, the electronic control unit determines, based on the build instructions, whether a repositioning of the print assembly 150 along the latitudinal axis is required. If repositioning is required, (at block 908, “Yes”), then at block 910, the electronic control unit transmits a control signal to the second actuator assembly 103 to reposition the print assembly 150 by a predetermined amount (e.g., a repositioning distance), for example, greater than zero and less than the jet spacing (d) (or any integer multiple of a fraction of the jet spacing (d)) defined by the build instructions. Referring to FIG. 21A and FIG. 21B , the repositioning distance is the distance from position I0to position Ii.

[0333] FIG. 30 The method 900 moves from block 910 to block 912. The print assembly 150 is moved again across the build area 120, this time in a second pass along the longitudinal axis in a second direction opposite the first direction, at block 912, the electronic control unit causes selected ones of the plurality of jetting nozzles 158 to dispense one or more drops of binding agent onto the build area 120. As described above, the binding agent can be dispensed at a number of sites and in various amounts on a layer of powder, corresponding to pixels defined in a deposition pattern as the print assembly traverses the longitudinal axis (e.g., the working axis 116).

[0334] As described above, the electronic control unit is communicatively coupled to one or more of the plurality of print heads 156, such that control signals generated by the electronic control unit cause the jetting nozzles associated with the print heads 156 to dispense binding agent or other material in predefined amounts at predefined sites as a deposition pattern (e.g., 125, FIG. 21C ) defines for a layer of powder being built. Referring briefly back to FIG. 21C The first pass of the print assembly 150 can deposit binding agent in the amounts and at the locations depicted by the illustrative representation of the deposition pattern 125. During the second pass, the jetting nozzles 158 (e.g., depicted in FIG. 21B ) are aligned with the second pass trajectory depicted in FIG. 21B without the hash marks utilized in

[0335] If repositioning of the print assembly is not required, (at block 908, “No”), then the method 900 proceeds to block 912, where the print assembly 150 can be moved across the build area in a second pass along the longitudinal axis in a second direction opposite the first direction, as described herein. FIG. 30 The method 900 depicted in may be repeated throughout the build of the component.

[0336] In some embodiments, the reference FIG. 30 The method 900 depicted and described, or in conjunction with the method 900, the reference FIG. 31 The method 1000 depicted and described can implement a predefined random indexing of the print assembly during the build to reduce the impact of a potentially malfunctioning print head 154 or jetting nozzle 158 on the overall quality and strength of the part being built.

[0337] The reference FIG. 31 , the method 1000 depicted and described using the reference FIG. 22A through FIG. 22B A flow diagram of an exemplary method 1000 of randomly indexing a print assembly 150 is described and depicted using a second actuator assembly. For brevity, to reduce repetition, blocks 1002-1004 of the method 1000 correspond to blocks 902-904 of the method 900 depicted and described with reference to the flow diagram of FIG. 9. FIG. 30

[0338] At block 1006, the electronic control unit causes the print assembly 150, including the at least one print head 156 and jetting nozzle 158, to traverse the build area 120 in a first pass trajectory in a first direction along the longitudinal axis. Additionally, the electronic control unit causes a selected jetting nozzle of the plurality of jetting nozzles 158 to dispense one or more drops of a binding agent or other material onto the build area 120. The electronic control unit is communicatively coupled to one or more of the plurality of print heads 156 such that control signals generated by the electronic control unit cause the jetting nozzles 158 associated with the print head 154 to dispense the binding agent or other material in a predefined amount at a predefined site as defined by a deposition pattern (e.g., 125, FIG. 21C ) for a layer of powder being built as the print assembly 150 traverses the build area 120. However, from time to time, for various reasons, a jetting nozzle 158 or print head 156 can malfunction, causing the binding agent or other material to not be applied in the prescribed manner. For example, with reference to FIG. 22A , both jetting nozzles 195a and 195b malfunction, they are unable to deposit the binding agent along their respective trajectories 190a and 190b as they traverse the build area 120. In other words, the malfunctioning jetting nozzles 195a and 195b are unable to deposit the binding agent at the prescribed site based on the deposition pattern defining the pixels, sub-pixels, and amount of binding agent to be deposited in each pixel. To reduce the impact of a part not receiving the binding agent or other material during a pass due to a malfunctioning print head 156 or jetting nozzle 158, the build instructions defined by the slicing engine can include a random shift or indexing of the print assembly 150 such that the same jetting nozzle 158 does not traverse the same trajectory on a subsequent pass, or at least not from time to time align with a different trajectory.

[0339] ​Thus, at block 1008, the electronic control unit determines whether a repositioning of the print assembly is prescribed by the build instructions and the corresponding predefined random repositioning distance. If no repositioning is prescribed at the completion of the print assembly 150's travel over the build area 120 (at block 1008, "No"), then the method proceeds to block 1012. If a repositioning is prescribed at the completion of the print assembly 150's travel over the build area 120 (at block 1008, "Yes"), then the method proceeds to block 1010. At block 1010, the electronic control unit transmits a control signal to the second actuator assembly 103 to cause the print assembly 150 to reposition by a predefined amount (e.g., a predefined integer multiple of the ejection pitch (d)), such that during one travel of the print assembly along the longitudinal axis, a first ejection nozzle 158 of the plurality of ejection nozzles 158 corresponding to a first travel trajectory assigned by the build instructions moves to correspond to a second travel trajectory and another ejection nozzle 158 corresponds to the first travel trajectory for a subsequent travel. See FIG. 22A for a description of the method 1000 depicted in FIG. 10. FIG. 22B At block 1010, the print assembly is repositioned by five ejection pitch (d) units, such that the ejection nozzle 158 moves five ejection pitch (d) units in the lateral direction. More specifically, now, the second failed ejection nozzle 195b corresponds to a new trajectory 191 that is opposite its previous trajectory 190b.

[0340] FIG. 31 The method 1000 from block 1010 moves to block 1012. The print assembly 150 again moves across the build area 120, this time in a second travel in a second direction opposite the first direction along the longitudinal axis, at which block 1012 the electronic control unit causes selected ejection nozzles of the plurality of ejection nozzles 158 to dispense one or more drops of the binding agent onto the build area 120. As described above, the binding agent can be dispensed within a pixel at several sites and in various amounts as the print assembly traverses the longitudinal axis (e.g., the working axis 116). FIG. 31 The method of the FIG. 1000 depicted in FIG. 10 can be repeated throughout the build of a part, and in some examples, in combination with the method 900 described in FIG. 9. FIG. 30

[0341] Referring now to FIG. 32 depicted is an illustrative flow diagram of a method 1100 for controlling binding agent bleed within a build of a part. In addition to controlling the sites and amounts of binding agent within a layer of a part built by the apparatus 100, there can be a need to control binding agent bleed. Binding agent bleed refers to instances in which binding agent propagates from an upper layer of a part to a lower layer before it has had a chance to cure or bind with the powder layer in which it was applied. As described above with reference to FIG. 23A through FIG. 23B ​As discussed, this can be a rate limiting parameter as to how quickly subsequent layers can be built. However, the methods described herein provide a solution to reduce or eliminate the rate limiting effect of adhesive bleed during a build operation utilizing the apparatus. As such, the part can be built at a faster rate than without implementing such methods and apparatus.

[0342] The methods described herein can be performed by the electronic control unit or computing device 15 implementing the slicing engine and / or other motion control generation code for building a part utilizing the apparatus 100. Reference is made to FIG. 32 At block 1102, the slicing engine can receive a model or drawing 200 of a part to be built. FIG. 23A The slicing engine incorporates logic defining build instructions, including generating executable instructions for the apparatus 100 to execute and build the modeled part. At block 1104, the slicing engine can first slice the model into a plurality of layers 210. FIG. 23B The part 220 can be an estimation of the actual dispersion behavior within the selected build material. As such, the part 220 can be estimated to have a thickness equal to, less than, or greater than the layer thickness and a surface area having a size of approximately the jet spacing (d). It should be appreciated that the part 220 can be further defined based on the properties of the adhesive and build material, the environment in which the part is being built (e.g., temperature, pressure, solidification energy source, etc.), the predicted or modeled interaction of the adhesive and build material. For purposes of explanation, the part 220 is assumed to have a cubic shape, however, this is for purposes of explanation only. At block 1108, the slicing engine can further identify the parts 220 that define a downward facing surface 221 of the part. These parts 220 that define a downward facing surface can be considered important with respect to controlling adhesive bleed because excess adhesive within these parts can result in poor surface finish. Once the layers, image voxels, and surface defining voxels are defined, the slicing engine can determine the volume of droplets of adhesive to be deposited within each part of powder (e.g., to achieve the desired voxel) within each layer of the part. At block 1110, the slicing engine determines the number of vertically adjacent voxels positioned above each first part that defines a downward facing surface 221.

[0343] At block 1112, the slice engine determines how to treat each of the vertically adjacent voxels relative to the amount of binder that should be applied. The determination can be made based on whether the number of vertically adjacent portions is less than, equal to, or greater than a predetermined thickness threshold. The thickness threshold can be predetermined based on the characteristics of the binder, the powder, the build speed, the part characteristics, whether or not to apply a solidification energy, the amount of time to apply it, the energy used to apply it, and / or other aspects of the build. Referring back to block 1112, if the number of vertically adjacent portions 222 is less than or equal to the predetermined thickness threshold, then the method 1100 proceeds to block 1114. On the other hand, at block 1112, if the number of vertically adjacent voxels is not less than the predetermined thickness threshold, then the method 1100 proceeds to block 1116.

[0344] At block 1114, the slice engine assigns a predetermined amount of binder for deposition within the first portion and each of the vertically adjacent portions. If the thickness threshold 240 is three, as depicted in FIG. 23 for example, then each of the vertically adjacent portions 222 is determined to receive the same amount of binder per voxel. However, if the number of vertically adjacent portions is not less than the predetermined thickness threshold, then at block 1116, the slice engine assigns an increased amount of binder for deposition from the first portion to each of the vertically adjacent portions within a decay length 230 of the predetermined amount of binder per portion. For example, the binder per portion in each of the vertically adjacent portions can be assigned linearly, exponentially, or other algorithmically proportionally based on the distance of the vertically adjacent portion from the portion defining the downward facing surface. Using the method 1100 or variations thereof to determine the droplet volume of binder per portion in the multiple portions extending from the downward facing surface 221, at block 1118, the slice engine generates a design deposition pattern (e.g., 125) for the binder per layer based on the vertically adjacent portions. The design deposition pattern can be executed by one or more of the methods and apparatuses described herein. FIG. 21C FIG. 21C

[0345] ​It should be appreciated that steps of the aforementioned processes can be omitted or performed in various orders while still achieving the objectives of the present disclosure. The functional blocks and / or flowchart elements described herein can be translated into machine-readable instructions. By way of non-limiting example, the machine-readable instructions can be written in any programming language, such as: (i) descriptive text to be parsed, such as hypertext markup language, extensible markup language, and the like, (ii) assembly language, (iii) object code generated from source code by a compiler, (iv) source code written in any suitable programming language to be executed by an interpreter, (v) source code to be compiled and executed by a just-in-time compiler, and the like. Alternatively, the machine-readable instructions can be written in a hardware description language (HDL), such as logic implemented via a field-programmable gate array (FPGA) configuration or an application-specific integrated circuit (ASIC) or its equivalent. As such, the functionality described herein can be implemented in any conventional computer programming language, as pre-programmed hardware elements, or as a combination of hardware and software components.

[0346] Based on the foregoing, it should be appreciated that the print assembly includes a support carriage and a first printhead row, the first printhead row including a first plurality of printheads spaced apart from one another in a direction transverse to a working axis of the print assembly. Each of the first plurality of printheads includes a plurality of ejection nozzles thereon. The print assembly further includes a second printhead row, the second printhead row including a second plurality of printheads spaced apart from one another in a direction transverse to the working axis. Each of the second plurality of printheads includes a plurality of ejection nozzles, and the first printhead row and the second printhead row are spaced apart along the working axis. The print assembly further includes an actuator coupled to a first printhead of the first plurality of printheads and configured to move the first printhead relative to the support carriage in a direction transverse to the working axis.

[0347] It is also understood that the manufacturing apparatus can include a print head having a plurality of ejection orifices spaced apart from one another in a direction transverse to the longitudinal axis, wherein a distance from a first ejection orifice of the plurality of ejection orifices to a second ejection orifice positioned adjacent the first ejection orifice defines an ejection pitch. The manufacturing apparatus can further include a print head position control assembly having a first actuator assembly configured to move the print head along the longitudinal axis and a second actuator assembly configured to move the print head along the latitudinal axis, and an electronic control unit communicatively coupled to the print head position control assembly. The electronic control unit can be configured to cause a selected ejection orifice of the plurality of ejection orifices to dispense one or more drops of adhesive while the print head traverses a first travel trajectory along the longitudinal axis in a first direction, to index the print head along the latitudinal axis by an indexing distance greater than zero and less than the ejection pitch to a second travel trajectory, and to cause the selected ejection orifice of the plurality of ejection orifices to dispense one or more drops of adhesive while the print head traverses the second travel trajectory along the longitudinal axis in a second direction opposite the first direction.

[0348] In further embodiments, a manufacturing apparatus can include at least one print head containing a plurality of ejection orifices spaced apart from one another in a direction transverse to the longitudinal axis, wherein a distance from a first ejection orifice of the plurality of ejection orifices to a second ejection orifice positioned adjacent the first ejection orifice defines an ejection pitch. A print head position control assembly of the manufacturing apparatus includes a first actuator configured to move the print head along the longitudinal axis and a second actuator configured to move the print head along the latitudinal axis. An electronic control unit communicatively coupled to the print head position control assembly is configured to cause a selected ejection orifice of the plurality of ejection orifices to dispense one or more drops of adhesive to a layer of powder in a deposition pattern defined by a slicing engine while the print head traverses the application of adhesive along the longitudinal axis, wherein the first ejection orifice of the plurality of ejection orifices corresponds to a first travel trajectory assigned by the slicing engine. The electronic control unit can further index the print head along the latitudinal axis by an integer number of pixels such that the first ejection orifice corresponds to a second travel trajectory and another ejection orifice corresponds to the first travel trajectory assigned by the slicing engine, and cause the indexed print head to traverse along the longitudinal axis and apply adhesive to the layer of powder in the deposition pattern defined by the slicing engine.

[0349] In still further embodiments, it will be appreciated that the manufacturing apparatus can include a print head containing a plurality of ejection ports spaced apart from one another in a direction transverse to the longitudinal axis, a print head position control assembly having a first actuator configured to move the print head along the longitudinal axis, and an electronic control unit communicatively coupled to the print head position control assembly. The electronic control unit is configured to cause selected ones of the plurality of ejection ports to dispense a predetermined volume of adhesive to a layer of powder in a deposition pattern defined by the slicing engine as the print head traverses the longitudinal axis to apply the adhesive, wherein an amount of adhesive dispensed in a first portion of powder in a first layer is less than an amount of adhesive dispensed in a portion of powder in a second layer positioned above the first portion of powder in the first layer.

[0350] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described herein came within the scope of the appended claims and their equivalents.

Claims

1. A manufacturing apparatus characterized by comprising: Comprising: a print head comprising a plurality of printheads comprising a plurality of ejection nozzles spaced apart from one another in a direction transverse to a longitudinal axis, the longitudinal axis being a working axis of the manufacturing apparatus, wherein a distance from a first ejection nozzle of the plurality of ejection nozzles to a second ejection nozzle positioned adjacent to the first ejection nozzle defines an ejection pitch; a print head position control assembly comprising a first actuator assembly configured to move the print head along the longitudinal axis and a second actuator assembly configured to move the print head along a latitudinal axis; and an electronic control unit communicatively coupled with the print head position control assembly, the electronic control unit configured to: cause selected ejection nozzles of the plurality of ejection nozzles to dispense one or more drops of a binding agent while the print head traverses a first travel trajectory along the longitudinal axis in a first direction; index the print head along the latitudinal axis to a second travel trajectory by an index distance greater than zero and less than the ejection pitch; and cause selected ejection nozzles of the plurality of ejection nozzles to dispense one or more drops of a binding agent while the print head traverses the second travel trajectory along the longitudinal axis in a second direction opposite the first direction; wherein: the print head comprises a plurality of printhead rows comprising a plurality of printheads of the plurality of printheads, and each printhead of the plurality of printhead rows comprises a plurality of ejection nozzles; the print head is sized and shaped to be slidably received therein by the plurality of printheads; the plurality of printheads are configured to be slidably translated within the plurality of printhead rows, respectively, in a transverse direction relative to the working axis; each printhead of the plurality of printheads comprises a coupling feature attached thereto, wherein the coupling feature of each printhead of the plurality of printheads of the plurality of printhead rows is further attached to an actuator; and the actuator attached to the coupling feature is configured to move a respective one of the plurality of printheads of a first printhead row and / or a second printhead row upon actuation of the actuator caused by execution of computer-readable and executable instructions stored in a non-transitory memory of the electronic control unit by the electronic control unit.

2. The manufacturing apparatus according to claim 1, characterized by wherein, a plurality of drops of a binding agent are dispensed within a pixel defining a 2-dimensional spatial portion of a layer of build material traversed by the print head.

3. The manufacturing apparatus according to claim 2, wherein wherein, drop volumes of the plurality of drops of a binding agent dispensed within the pixel are different.

4. The manufacturing apparatus according to claim 2, wherein wherein, drop volumes of the plurality of drops of a binding agent dispensed within the pixel and a location within the pixel are different.

5. The manufacturing apparatus according to claim 1, wherein wherein, a predefined total amount of binding agent for dispensing within a pixel is dispensed over at least two passes of the print head as a fraction of a total amount of binding agent.

6. The manufacturing apparatus according to claim 1, wherein wherein, the index distance is half of the ejection pitch.

7. The manufacturing apparatus according to claim 1, wherein wherein, the index distance is an integer multiple of a fractional value of the ejection pitch.

8. The manufacturing apparatus according to claim 1, wherein wherein, The first printhead row includes the set of multiple printheads, which are spaced apart from each other in a direction transverse to the working axis; and The first actuator of the first printhead, which is connected to the plurality of printheads, is configured to move the first printhead along the latitudinal axis.

9. The manufacturing apparatus according to claim 8, wherein in, The electronic control unit is further configured to: One or more of the plurality of printheads are rotated to the second travel trajectory along the lateral axis by a rotation distance greater than zero and less than the jet spacing.

10. The manufacturing apparatus according to claim 8, wherein in, The actuator is one of a plurality of actuators, wherein each of the plurality of actuators is coupled to a printhead among the plurality of printheads.

11. A manufacturing apparatus characterized by comprising: Include: A printhead comprising a plurality of print heads, the plurality of print heads comprising a plurality of jet nozzles spaced apart from each other in a direction transverse to a longitudinal axis, the longitudinal axis being the working axis of the manufacturing equipment, wherein the distance from a first jet nozzle to a second jet nozzle positioned adjacent to the first jet nozzle defines the jet spacing. A printhead position control assembly, comprising a first actuator assembly and a second actuator assembly, the first actuator assembly being configured to move the printhead along the longitudinal axis, and the second actuator assembly being configured to move the printhead along the latitudinal axis; and An electronic control unit, communicatively connected to the printhead position control assembly, is configured to: When the printhead applies adhesive across the longitudinal axis, a selected nozzle among the plurality of nozzles dispenses more than one drop of adhesive onto the powder layer in a deposition pattern defined by the slicing engine, wherein the first nozzle among the plurality of nozzles corresponds to a first trajectory assigned by the slicing engine. The printing head is rotated along the lateral axis by a displacement distance, such that the first jet nozzle corresponds to the second stroke trajectory, and the other jet nozzle corresponds to the first trajectory assigned by the slicing engine; and The transposed printhead traverses along the longitudinal axis and applies adhesive to the powder layer in the deposition pattern defined by the slicing engine; in: The printhead includes multiple printhead rows, each printhead row including a group of multiple printheads, and each printhead in the multiple printhead rows including multiple jet nozzles; The printhead is sized and shaped to receive the plurality of printheads slidably therein; The plurality of printheads are configured to be slidably translated in the plurality of printhead rows in a lateral direction relative to the working axis; Each of the plurality of printheads includes a coupling feature attached thereto, wherein the coupling feature of each of the plurality of printheads in the plurality of printhead rows is further attached to an actuator; and The actuator attached to the coupling feature is configured to move a respective one of the plurality of print heads in the first print head row and / or the second print head row upon actuation of the actuator caused by execution of computer readable and executable instructions stored in a non-transitory memory of the electronic control unit by the electronic control unit.

12. The manufacturing apparatus according to claim 11, wherein wherein, The step of indexing the print head along the latitudinal axis occurs between a first pass and a second pass on the same layer of powder.

13. The manufacturing apparatus according to claim 11, wherein wherein, The step of indexing the print head along the latitudinal axis occurs after adhesive application to a first layer of powder and before adhesive application to a subsequent layer of powder.

14. The manufacturing apparatus of claim 11, wherein, further comprising an in-situ monitoring system configured to: determine malfunctioning of one or more of the plurality of jetting nozzles, and provide a notification signal to the electronic control unit identifying the one or more malfunctioning jetting nozzles.

15. The manufacturing apparatus of claim 14, wherein wherein, the electronic control unit is further configured to: develop one or more indexing commands for indexing the print head between predefined passes such that a malfunctioning jetting nozzle configured to be determined to be in a malfunctioning state does not traverse the same trajectory during a subsequent pass.

16. The manufacturing apparatus of claim 14, wherein, the electronic control unit is further configured to: develop one or more indexing commands for indexing the print head between predefined passes such that a malfunctioning jetting nozzle does not traverse a trajectory defining an edge of the deposition pattern for a printed part.

17. The manufacturing apparatus of claim 11, wherein wherein, the slicing engine defines at least a predetermined number of layers and the deposition pattern of adhesive for a printed part.

18. The manufacturing apparatus of claim 11, wherein, wherein: the first print head row comprises the set of plurality of print heads spaced apart from each other in a direction transverse to the working axis; and a first actuator coupled to a first print head of the plurality of print heads is configured to move the first print head along the latitudinal axis.

19. The manufacturing apparatus of claim 18, wherein wherein, the electronic control unit is further configured to: index one or more of the plurality of print heads along the latitudinal axis to the second pass trajectory by an indexing distance along the latitudinal axis such that the first jetting nozzle corresponds to the second pass trajectory and another jetting nozzle corresponds to the first trajectory assigned by the slicing engine.

20. The manufacturing apparatus of claim 18, wherein, wherein: the actuator is one of a plurality of actuators, wherein each actuator of the plurality of actuators is coupled to a print head of the plurality of print heads.

21. A manufacturing apparatus characterized by comprising: comprising: a print head comprising a plurality of print heads comprising a plurality of jetting nozzles spaced apart from each other in a direction transverse to a longitudinal axis, the longitudinal axis being a working axis of the manufacturing apparatus; a print head position control assembly comprising a first actuator assembly configured to move the print head along the longitudinal axis; and an electronic control unit communicatively coupled with the print head position control assembly, the electronic control unit configured to: while the print head traverses the longitudinal axis to apply the adhesive, selected ones of the plurality of jetting nozzles dispense a predetermined volume of adhesive to the powder layer in a deposition pattern defined by the slicing engine, wherein an amount of adhesive dispensed in a first portion of powder in a first layer is less than an amount of adhesive in a portion of powder in a second layer positioned above the first portion of powder in the first layer; wherein: the print head comprises a plurality of print head rows, the plurality of print head rows comprising a group of the plurality of print heads, and each print head in the plurality of print head rows comprises a plurality of jetting nozzles; the print head is sized and shaped to be slidably received therein the plurality of print heads; the plurality of print heads are configured to be slidably translated within the plurality of print head rows, respectively, in a transverse direction relative to the working axis; each print head in the plurality of print heads comprises a coupling feature attached thereto, wherein the coupling feature of each print head in the plurality of print heads in the plurality of print head rows is further attached to an actuator; and the actuator attached to the coupling feature is configured to move a respective one of the plurality of print heads in the first print head row and / or the second print head row upon actuation of the actuator caused by execution of computer readable and executable instructions stored in a non-transitory memory of the electronic control unit by the electronic control unit.

22. The manufacturing apparatus of claim 21, wherein, wherein, the amount of adhesive dispensed in successively aligned portions of powder in subsequent layers of powder gradually increases to a predetermined volume.

23. The manufacturing apparatus of claim 21, wherein wherein, the amount of adhesive dispensed in successively aligned portions of powder in subsequent layers of powder gradually increases beyond a decay length defined by a predetermined number of layers of powder.

24. The manufacturing apparatus of claim 21, wherein, wherein, when the predetermined number of layers is greater than a predetermined thickness threshold, the amount of adhesive dispensed in successively aligned portions of powder in subsequent layers of powder gradually increases beyond a decay length defined by the predetermined number of layers of powder.

25. The manufacturing apparatus of claim 21, wherein wherein, the amount of adhesive dispensed in successively aligned portions of powder in subsequent layers is based on one or more properties of the powder material.

26. The manufacturing apparatus of claim 21, wherein wherein, the amount of adhesive dispensed in successively aligned portions of powder in subsequent layers is based on a bulk density of the powder material.

27. The manufacturing apparatus of claim 21, wherein wherein, the amount of adhesive dispensed in successively aligned portions of powder in subsequent layers is based on an amount of time for wicking of the adhesive prior to solidification.

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