PARC, A Xerox Company, has been working on developing a new method of additive manufacturing that would solve many problems with todays methods. Polymer Spray Deposition (PSD) combines a unique aerosol generation system with a digital electrostatic printing method to create full 3D objects from conventional injection molding grade thermoplastics. In order to create a feedstock aerosol for electrostatic deposition, PARC has developed the filament extension atomizer (FEA) which is capable of producing monodisperse small droplets from thermoplastics. These droplets are then carried downstream where they are charged, and then through digital electrostatic patterning, selectively deposited on a substrate, digitally constructing 3D objects from thermoplastics, layer by layer. We will present modelling and experimental data on many of the elements required to make the process viable. These will include experimental spray production, modelling of electrostatic processes, and initial experimental demonstrations towards a viable print process.
Johnson, D. M.; Chang, N. E.; Volkel, A. R.; Elrod, S. A.; Biegelsen, D. K.; Jose, A. Polymer Spray Deposition: A Novel Aerosol-Based, Electrostatic Digital Deposition System for Additive Manufacturing. Printing for Fabrication. 9/14/2016