Thermwood Corporation

United States of America

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IPC Class
B33Y 10/00 - Processes of additive manufacturing 71
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor 62
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM] 49
B29C 64/209 - Heads; Nozzles 41
B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material 40
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1.

METHODS AND APPARATUS FOR COMPRESSING MATERIAL DURING ADDITIVE MANUFACTURING

      
Application Number 18419036
Status Pending
Filing Date 2024-01-22
First Publication Date 2024-05-16
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B29C 64/218 - Rollers

2.

MACHINE AND METHOD FOR FORMING ARTICLES

      
Application Number 18529979
Status Pending
Filing Date 2023-12-05
First Publication Date 2024-04-18
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded materiaL

IPC Classes  ?

  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 43/20 - Making multilayered or multicoloured articles
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/25 - Housings, e.g. machine housings

3.

METHODS AND APPARATUS FOR PROCESSING AND DISPENSING MATERIAL DURING ADDITIVE MANUFACTURING

      
Application Number 18529991
Status Pending
Filing Date 2023-12-05
First Publication Date 2024-03-28
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vote, Nicolas
  • Gaesser, Robert
  • Smiddy, Brian S.
  • Vaal, Scott G.

Abstract

A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

4.

APPARATUS AND METHODS FOR FABRICATING COMPONENTS

      
Application Number 18497646
Status Pending
Filing Date 2023-10-30
First Publication Date 2024-02-22
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering

5.

SYSTEMS AND METHODS FOR PRINTING COMPONENTS USING ADDITIVE MANUFACTURING

      
Application Number 18352882
Status Pending
Filing Date 2023-07-14
First Publication Date 2024-01-18
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Vote, Nicolas C.

Abstract

A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.

IPC Classes  ?

  • B29C 64/227 - Driving means
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • G05B 19/414 - Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller

6.

METHOD OF PRODUCING PATTERNS, MOLDS, AND RELATED PRODUCTS

      
Application Number 18325833
Status Pending
Filing Date 2023-05-30
First Publication Date 2023-10-12
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.

IPC Classes  ?

  • B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

7.

APPARATUS AND METHOD FOR DEPOSITING MATERIAL DURING ADDITIVE MANUFACTURING

      
Application Number 18180621
Status Pending
Filing Date 2023-03-08
First Publication Date 2023-09-28
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, Jonathan L.

Abstract

An additive manufacturing apparatus an extruder configured to receive material, a work surface extending so as to define a plane for receiving one or more layers of the material, an applicator assembly secured at a downstream portion of the additive manufacturing apparatus, a nozzle connected to the applicator assembly, the nozzle being configured to receive the material from the extruder and deposit the material on the work surface, and an actuator configured to displace the work surface in a movement direction, wherein the movement direction forms an acute angle with the plane.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/218 - Rollers
  • B33Y 10/00 - Processes of additive manufacturing
  • B29K 101/12 - Thermoplastic materials

8.

Methods and apparatus for processing and dispensing material during additive manufacturing

      
Application Number 18173877
Grant Number 11872752
Status In Force
Filing Date 2023-02-24
First Publication Date 2023-07-13
Grant Date 2024-01-16
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vote, Nicolas
  • Gaesser, Robert
  • Smiddy, Brian S.
  • Vaal, Scott G.

Abstract

A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing

9.

Methods and systems for increasing print speed during additive manufacturing

      
Application Number 18180577
Grant Number 11865788
Status In Force
Filing Date 2023-03-08
First Publication Date 2023-07-13
Grant Date 2024-01-09
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/364 - Conditioning of environment

10.

Near net shape additive manufacturing apparatus

      
Application Number 18188034
Grant Number 11969936
Status In Force
Filing Date 2023-03-22
First Publication Date 2023-07-13
Grant Date 2024-04-30
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John

Abstract

An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/245 - Platforms or substrates
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

11.

Apparatus and method for depositing material during additive manufacturing

      
Application Number 17656318
Grant Number 11618209
Status In Force
Filing Date 2022-03-24
First Publication Date 2023-04-04
Grant Date 2023-04-04
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, Jonathan L.

Abstract

An additive manufacturing apparatus an extruder configured to receive material, a work surface extending so as to define a plane for receiving one or more layers of the material, an applicator assembly secured at a downstream portion of the additive manufacturing apparatus, a nozzle connected to the applicator assembly, the nozzle being configured to receive the material from the extruder and deposit the material on the work surface, and an actuator configured to displace the work surface in a movement direction, wherein the movement direction forms an acute angle with the plane.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/218 - Rollers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29K 101/12 - Thermoplastic materials

12.

Machine and method for forming articles

      
Application Number 18045048
Grant Number 11865760
Status In Force
Filing Date 2022-10-07
First Publication Date 2023-02-23
Grant Date 2024-01-09
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.

IPC Classes  ?

  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 43/20 - Making multilayered or multicoloured articles
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29L 9/00 - Layered products
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns

13.

Feed housing purge system

      
Application Number 17813545
Grant Number 11554538
Status In Force
Filing Date 2022-07-19
First Publication Date 2023-01-17
Grant Date 2023-01-17
Owner Thermwood Corporation (USA)
Inventor
  • Smiddy, Brian S.
  • Vaal, Scott G.

Abstract

An additive manufacturing apparatus includes a material container having a hollow interior configured to receive a material and an extruder connected below the material container to receive the material from the material container. The additive manufacturing apparatus includes a material removal device including an actuator configured to activate the material removal device to dislodge retained material from within the hollow interior of the material container and a drain passage configured to receive the dislodged material and guide the material to an exterior of the additive manufacturing apparatus.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/35 - Cleaning
  • B29C 64/209 - Heads; Nozzles
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/314 - Preparation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/329 - Feeding using hoppers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting

14.

Methods and systems for increasing print speed during additive manufacturing

      
Application Number 17930135
Grant Number 11618218
Status In Force
Filing Date 2022-09-07
First Publication Date 2022-12-29
Grant Date 2023-04-04
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/364 - Conditioning of environment
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

15.

Method of producing patterns, molds, and related products

      
Application Number 17661202
Grant Number 11701818
Status In Force
Filing Date 2022-04-28
First Publication Date 2022-11-17
Grant Date 2023-07-18
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.

IPC Classes  ?

  • B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 10/00 - Processes of additive manufacturing
  • B29K 101/10 - Thermosetting resins

16.

Feed housing purge system

      
Application Number 17513125
Grant Number 11472108
Status In Force
Filing Date 2021-10-28
First Publication Date 2022-10-18
Grant Date 2022-10-18
Owner THERMWOOD CORPORATION (USA)
Inventor
  • Smiddy, Brian S.
  • Vaal, Scott G.

Abstract

An additive manufacturing apparatus includes a material container having a hollow interior configured to receive a material and an extruder connected below the material container to receive the material from the material container. The additive manufacturing apparatus includes a material removal device including an actuator configured to activate the material removal device to dislodge retained material from within the hollow interior of the material container and a drain passage configured to receive the dislodged material and guide the material to an exterior of the additive manufacturing apparatus.

IPC Classes  ?

  • B29C 64/329 - Feeding using hoppers
  • B29C 64/35 - Cleaning
  • B29C 64/209 - Heads; Nozzles
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/314 - Preparation

17.

Methods and apparatus for processing and dispensing material during additive manufacturing

      
Application Number 17806618
Grant Number 11607845
Status In Force
Filing Date 2022-06-13
First Publication Date 2022-09-29
Grant Date 2023-03-21
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vote, Nicolas
  • Gaesser, Robert
  • Smiddy, Brian S.
  • Vaal, Scott G.

Abstract

A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing

18.

Apparatus and methods for fabricating components

      
Application Number 17805427
Grant Number 11850789
Status In Force
Filing Date 2022-06-03
First Publication Date 2022-09-15
Grant Date 2023-12-26
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth

Abstract

An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29K 101/12 - Thermoplastic materials
  • B29C 64/245 - Platforms or substrates
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

19.

Apparatus for near net shape additive manufacturing

      
Application Number 17653531
Grant Number 11628614
Status In Force
Filing Date 2022-03-04
First Publication Date 2022-06-16
Grant Date 2023-04-18
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John

Abstract

An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29C 64/245 - Platforms or substrates
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control

20.

Method of producing patterns, molds, and related products

      
Application Number 17322477
Grant Number 11345081
Status In Force
Filing Date 2021-05-17
First Publication Date 2022-05-31
Grant Date 2022-05-31
Owner THERMWOOD CORPORATION (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.

IPC Classes  ?

  • B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 10/00 - Processes of additive manufacturing
  • B29K 101/10 - Thermosetting resins

21.

Systems and methods for printing components using additive manufacturing

      
Application Number 17645549
Grant Number 11724453
Status In Force
Filing Date 2021-12-22
First Publication Date 2022-04-14
Grant Date 2023-08-15
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Vote, Nicolas C.

Abstract

A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.

IPC Classes  ?

  • B29C 64/227 - Driving means
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • G05B 19/41 - Numerical control (NC), i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by interpolation, e.g. the computation of intermediate points between programmed end points to define the path to be followed and the rate of travel along that path
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • G05B 19/414 - Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller

22.

Apparatus and methods for fabricating components

      
Application Number 17541050
Grant Number 11376778
Status In Force
Filing Date 2021-12-02
First Publication Date 2022-03-24
Grant Date 2022-07-05
Owner THERMWOOD CORPORATION (USA)
Inventor Susnjara, Kenneth

Abstract

An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29K 101/12 - Thermoplastic materials
  • B29C 64/245 - Platforms or substrates
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

23.

Systems and methods for producing parts at elevated temperatures

      
Application Number 17517143
Grant Number 11931932
Status In Force
Filing Date 2021-11-02
First Publication Date 2022-02-24
Grant Date 2024-03-19
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A mold assembly for producing a part includes a first section, a second section movably coupled to the first section, and a cavity defined by the first section and the second section, the cavity being shaped to receive a part while the first section and the second section are movably coupled to each other. The mold assembly includes a joint formed by adjacent surfaces of the first section and the second section and a seal extending along the joint.

IPC Classes  ?

  • B29C 43/36 - Moulds for making articles of definite length, i.e. discrete articles
  • B29C 35/02 - Heating or curing, e.g. crosslinking or vulcanising
  • B29C 43/02 - Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
  • B29C 64/10 - Processes of additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • B29K 101/12 - Thermoplastic materials

24.

APPARATUS AND METHOD FOR PRINTING LARGE THERMOPLASTIC PARTS DURING ADDITIVE MANUFACTURING

      
Application Number 17452436
Status Pending
Filing Date 2021-10-27
First Publication Date 2022-02-10
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Smiddy, Brian S.
  • Fuquay, Jonathan I.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder, the extruder having an opening dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle in fluid communication with the gear pump for depositing the at least partially melted material.

IPC Classes  ?

  • B29C 64/295 - Heating elements
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/241 - Driving means for rotary motion
  • B29C 48/285 - Feeding the extrusion material to the extruder
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/205 - Means for applying layers
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/227 - Driving means
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer

25.

WARP COMPENSATION FOR ADDITIVE MANUFACTURING

      
Application Number 17509243
Status Pending
Filing Date 2021-10-25
First Publication Date 2022-02-10
Owner Thernwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes receiving a design model indicative of a part that may be fabricated using the additive manufacturing method, and generating expected-warping information based on the design model, the expected-warping information being indicative of an expected change in a shape of the part resulting from the additive manufacturing method. The method also includes modifying the design model based on the expected-warping information and fabricating the part using the modified design model.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]

26.

Systems and methods for greater inter-layer bond integrity in additive manufacturing

      
Application Number 17200120
Grant Number 11241841
Status In Force
Filing Date 2021-03-12
First Publication Date 2022-02-08
Grant Date 2022-02-08
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, Jonathan I.
  • Lough, Joshua A.

Abstract

An additive manufacturing apparatus includes an extruder configured to receive a thermoplastic material and an applicator assembly downstream of the extruder, the applicator assembly including a nozzle for depositing the thermoplastic material as a plurality of layers. The additive manufacturing apparatus also includes a temperature sensor configured to detect a temperature of at least a portion of a deposited layer and a positioning assembly configured to change an angular position of the temperature sensor.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing

27.

Methods and systems for increasing print speed during additive manufacturing

      
Application Number 16917194
Grant Number 11465362
Status In Force
Filing Date 2020-06-30
First Publication Date 2021-12-30
Grant Date 2022-10-11
Owner THERMWOOD CORPORATION (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]

28.

Systems and methods for producing parts at elevated temperatures

      
Application Number 16915624
Grant Number 11207808
Status In Force
Filing Date 2020-06-29
First Publication Date 2021-12-28
Grant Date 2021-12-28
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A mold assembly for producing a part includes a first section, a second section movably coupled to the first section, and a cavity defined by the first section and the second section, the cavity being shaped to receive a part while the first section and the second section are movably coupled to each other. The mold assembly includes a joint formed by adjacent surfaces of the first section and the second section and a seal extending along the joint.

IPC Classes  ?

  • B29C 43/36 - Moulds for making articles of definite length, i.e. discrete articles
  • B29C 43/02 - Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
  • B29C 35/02 - Heating or curing, e.g. crosslinking or vulcanising
  • B29C 64/10 - Processes of additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • B29K 101/12 - Thermoplastic materials

29.

Near net shape additive manufacturing

      
Application Number 17402820
Grant Number 11298873
Status In Force
Filing Date 2021-08-16
First Publication Date 2021-12-09
Grant Date 2022-04-12
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John

Abstract

An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29C 64/245 - Platforms or substrates
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control

30.

Methods and apparatus for processing and dispensing material during additive manufacturing

      
Application Number 17396391
Grant Number 11383438
Status In Force
Filing Date 2021-08-06
First Publication Date 2021-11-25
Grant Date 2022-07-12
Owner THERMWOOD CORPORATION (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vote, Nicolas
  • Gaesser, Robert
  • Smiddy, Brian S.
  • Vaal, Scott G.

Abstract

A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing

31.

Methods and apparatus for compressing material during additive manufacturing

      
Application Number 17365352
Grant Number 11911953
Status In Force
Filing Date 2021-07-01
First Publication Date 2021-11-11
Grant Date 2024-02-27
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B29C 64/218 - Rollers
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

32.

Apparatus and method for thermal compensation during additive manufacturing

      
Application Number 17375725
Grant Number 11993012
Status In Force
Filing Date 2021-07-14
First Publication Date 2021-11-11
Grant Date 2024-05-28
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John
  • Vaal, Scott G.

Abstract

An additive manufacturing apparatus includes an extruder and a gear pump in fluid communication with extruder. The additive manufacturing apparatus also includes a nozzle in fluid communication with the gear pump. The extruder is connected to a guide member such that at least a portion of the extruder is configured to expand and move along the guide member according to a thermal expansion of the extruder.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B22F 10/18 - Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
  • B22F 12/53 - Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/205 - Means for applying layers
  • B29C 64/227 - Driving means
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/25 - Housings, e.g. machine housings
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

33.

METHODS AND APPARATUS FOR COMPENSATING FOR MATERIAL DISTORTION DURING ADDITIVE MANUFACTURING

      
Application Number 17373910
Status Pending
Filing Date 2021-07-13
First Publication Date 2021-11-04
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up

34.

Methods and apparatus for compensating for thermal expansion during additive manufacturing

      
Application Number 17370296
Grant Number 11491739
Status In Force
Filing Date 2021-07-08
First Publication Date 2021-10-28
Grant Date 2022-11-08
Owner THERMWOOD CORPORATION (USA)
Inventor Susnjara, Kenneth J.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.

IPC Classes  ?

  • B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B26D 5/00 - Arrangements for operating and controlling machines or devices for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
  • B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • G01B 11/00 - Measuring arrangements characterised by the use of optical techniques
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
  • B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
  • B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/141 - Processes of additive manufacturing using only solid materials
  • B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
  • G01B 5/00 - Measuring arrangements characterised by the use of mechanical techniques
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29L 31/00 - Other particular articles
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles

35.

Additive manufacturing system and method of servicing

      
Application Number 17356022
Grant Number 11833752
Status In Force
Filing Date 2021-06-23
First Publication Date 2021-10-14
Grant Date 2023-12-05
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John
  • Vaal, Scott G.

Abstract

An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/141 - Processes of additive manufacturing using only solid materials
  • B29C 64/227 - Driving means
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/218 - Rollers
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

36.

Machine and method for forming articles

      
Application Number 17322540
Grant Number 11491696
Status In Force
Filing Date 2021-05-17
First Publication Date 2021-09-02
Grant Date 2022-11-08
Owner THERMWOOD CORPORATION (USA)
Inventor Susnjara, Kenneth J.

Abstract

A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.

IPC Classes  ?

  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 43/20 - Making multilayered or multicoloured articles
  • B29L 9/00 - Layered products

37.

Methods and systems for producing boat components

      
Application Number 16917047
Grant Number 11104402
Status In Force
Filing Date 2020-06-30
First Publication Date 2021-08-31
Grant Date 2021-08-31
Owner THERMWOOD CORPORATION (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method ay includes depositing thermoplastic material with an additive manufacturing apparatus to form a first section of a mold of a marine article. The first section includes an interior surface having a shape corresponding to a first portion of a hull of the marine article and a support portion including a support surface, the support portion being integrally formed with the interior surface. The method also includes depositing thermoplastic material to form a second section of a mold of a marine article, the second section including an interior surface having a shape corresponding to a second portion of a hull of the marine article. The method also includes joining the first section and the first section together to form at least a portion of the mold.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B63B 5/24 - Hulls characterised by their construction of non-metallic material made predominantly of plastics
  • B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing

38.

Systems and methods for printing components using additive manufacturing

      
Application Number 17225769
Grant Number 11235524
Status In Force
Filing Date 2021-04-08
First Publication Date 2021-07-22
Grant Date 2022-02-01
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Vote, Nicolas C.

Abstract

A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.

IPC Classes  ?

  • G05B 19/41 - Numerical control (NC), i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by interpolation, e.g. the computation of intermediate points between programmed end points to define the path to be followed and the rate of travel along that path
  • B29C 64/227 - Driving means
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • G05B 19/414 - Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

39.

Apparatus and method for printing large thermoplastic parts during additive manufacturing

      
Application Number 17160074
Grant Number 11179893
Status In Force
Filing Date 2021-01-27
First Publication Date 2021-06-17
Grant Date 2021-11-23
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Smiddy, Brian S.
  • Fuquay, Jonathan I.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder, the extruder having an opening dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle in fluid communication with the gear pump for depositing the at least partially melted material.

IPC Classes  ?

  • B29C 64/295 - Heating elements
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/241 - Driving means for rotary motion
  • B29C 48/285 - Feeding the extrusion material to the extruder
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/205 - Means for applying layers
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/227 - Driving means
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/218 - Rollers
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 48/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor

40.

Apparatus and methods for fabricating components

      
Application Number 17172845
Grant Number 11220097
Status In Force
Filing Date 2021-02-10
First Publication Date 2021-06-03
Grant Date 2022-01-11
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth

Abstract

An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29K 101/12 - Thermoplastic materials
  • B29C 64/245 - Platforms or substrates
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

41.

Near net shape additive manufacturing

      
Application Number 17021730
Grant Number 11117313
Status In Force
Filing Date 2020-09-15
First Publication Date 2021-05-27
Grant Date 2021-09-14
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John

Abstract

An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/245 - Platforms or substrates
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/25 - Housings, e.g. machine housings

42.

Methods and systems for producing boat molds by additive manufacturing

      
Application Number 16796366
Grant Number 11014291
Status In Force
Filing Date 2020-02-20
First Publication Date 2021-05-25
Grant Date 2021-05-25
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes providing material to an extruder of an additive manufacturing apparatus, heating the material to form a flowable material, and depositing a first layer of the flowable material from a nozzle of the additive manufacturing apparatus to form part of a hull portion of a plug for a marine article. The method also includes depositing a second layer of the flowable material from the nozzle of the additive manufacturing apparatus to form part of a deck portion of the plug for the marine article.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • B33Y 80/00 - Products made by additive manufacturing
  • B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof

43.

Method and system for z-axis impact resistance for machining

      
Application Number 17125196
Grant Number 11003160
Status In Force
Filing Date 2020-12-17
First Publication Date 2021-05-11
Grant Date 2021-05-11
Owner Thermwood Corporation (USA)
Inventor Smiddy, Brian S.

Abstract

A multi-axis machine includes a horizontally-displaceable carriage, a vertically-displaceable column, a spindle supported distally of the column, a motor configured to change a position of at least one of the carriage, the column, or the spindle; and an impact detection mechanism. The impact detection mechanism includes a first plate, a second plate secured distally of the first plate, and a sensor configured to detect a motion of the second plate with respect to the first plate.

IPC Classes  ?

  • G05B 19/4061 - Avoiding collision or forbidden zones
  • B23Q 15/12 - Adaptive control, i.e. adjusting itself to have a performance which is optimum according to a preassigned criterion

44.

Warp compensation for additive manufacturing

      
Application Number 16596305
Grant Number 11155039
Status In Force
Filing Date 2019-10-08
First Publication Date 2021-04-08
Grant Date 2021-10-26
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An additive manufacturing method includes receiving a design model indicative of a part that may be fabricated using the additive manufacturing method, and generating expected-warping information based on the design model, the expected-warping information being indicative of an expected change in a shape of the part resulting from the additive manufacturing method. The method also includes modifying the design model based on the expected-warping information and fabricating the part using the modified design model.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/10 - Processes of additive manufacturing
  • G06F 30/20 - Design optimisation, verification or simulation
  • G06F 111/10 - Numerical modelling
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing

45.

Apparatus and method for thermal compensation during additive manufacturing

      
Application Number 17013062
Grant Number 11077616
Status In Force
Filing Date 2020-09-04
First Publication Date 2021-04-08
Grant Date 2021-08-03
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John
  • Vaal, Scott G.

Abstract

An additive manufacturing apparatus includes an extruder and a gear pump in fluid communication with extruder. The additive manufacturing apparatus also includes a nozzle in fluid communication with the gear pump. The extruder is connected to a guide member such that at least a portion of the extruder is configured to expand and move along the guide member according to a thermal expansion of the extruder.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/205 - Means for applying layers
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/227 - Driving means
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

46.

Methods and apparatus for compensating for material distortion during additive manufacturing

      
Application Number 17067376
Grant Number 11077606
Status In Force
Filing Date 2020-10-09
First Publication Date 2021-01-28
Grant Date 2021-08-03
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

47.

Methods and apparatus for compressing material during additive manufacturing

      
Application Number 16935981
Grant Number 11065808
Status In Force
Filing Date 2020-07-22
First Publication Date 2021-01-14
Grant Date 2021-07-20
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B29C 64/218 - Rollers
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

48.

Apparatus and methods for compressing material during additive manufacturing

      
Application Number 17013220
Grant Number 11220053
Status In Force
Filing Date 2020-09-04
First Publication Date 2020-12-24
Grant Date 2022-01-11
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Smiddy, Brian S.

Abstract

Embodiments of the present disclosure are drawn to an additive manufacturing system, which may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. An applicator head may surround at least a portion of a proximal region of the nozzle. The applicator head may include a housing, a cooling inlet for receiving a coolant into the housing, a cooling outlet configured to allow the coolant to exit the housing, and an air inlet. A roller may be mounted on the applicator head to one side of the outlet of the nozzle. The roller may include an air outlet, wherein a flow path connects the air inlet and the air outlet so that air enters the air inlet and exits the air outlet. The roller may also include a plurality of holes located on an external surface of the roller.

IPC Classes  ?

  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/245 - Platforms or substrates
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 101/12 - Thermoplastic materials

49.

Methods and apparatus for compensating for thermal expansion during additive manufacturing

      
Application Number 17002513
Grant Number 11072162
Status In Force
Filing Date 2020-08-25
First Publication Date 2020-12-10
Grant Date 2021-07-27
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.

IPC Classes  ?

  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B26D 5/00 - Arrangements for operating and controlling machines or devices for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
  • B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • G01B 11/00 - Measuring arrangements characterised by the use of optical techniques
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
  • B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
  • B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/141 - Processes of additive manufacturing using only solid materials
  • B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
  • G01B 5/00 - Measuring arrangements characterised by the use of mechanical techniques
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29L 31/00 - Other particular articles
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles

50.

Print head for additive manufacturing

      
Application Number 16917303
Grant Number 11059227
Status In Force
Filing Date 2020-06-30
First Publication Date 2020-10-22
Grant Date 2021-07-13
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John
  • Vaal, Scott G.

Abstract

An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/141 - Processes of additive manufacturing using only solid materials
  • B29C 64/227 - Driving means
  • B29C 64/218 - Rollers
  • B29C 64/25 - Housings, e.g. machine housings
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

51.

Near net shape additive manufacturing

      
Application Number 16692825
Grant Number 10786944
Status In Force
Filing Date 2019-11-22
First Publication Date 2020-09-29
Grant Date 2020-09-29
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John

Abstract

An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29C 64/245 - Platforms or substrates
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/25 - Housings, e.g. machine housings

52.

Apparatus and methods for fabricating components

      
Application Number 16900127
Grant Number 10940681
Status In Force
Filing Date 2020-06-12
First Publication Date 2020-09-24
Grant Date 2021-03-09
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth

Abstract

An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

IPC Classes  ?

  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29K 101/12 - Thermoplastic materials
  • B29C 64/245 - Platforms or substrates
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

53.

Apparatus and method for thermal compensation during additive manufacturing

      
Application Number 16596089
Grant Number 10780635
Status In Force
Filing Date 2019-10-08
First Publication Date 2020-09-22
Grant Date 2020-09-22
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John
  • Vaal, Scott G.

Abstract

An additive manufacturing apparatus includes an extruder and a gear pump in fluid communication with extruder. The additive manufacturing apparatus also includes a nozzle in fluid communication with the gear pump. The extruder is connected to a guide member such that at least a portion of the extruder is configured to expand and move along the guide member according to a thermal expansion of the extruder.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/227 - Driving means
  • B29C 64/205 - Means for applying layers
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing

54.

Methods and apparatus for processing and dispensing material during additive manufacturing

      
Application Number 16877864
Grant Number 11104072
Status In Force
Filing Date 2020-05-19
First Publication Date 2020-09-03
Grant Date 2021-08-31
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vote, Nicolas
  • Gaesser, Robert
  • Smiddy, Brian S.
  • Vaal, Scott G.

Abstract

A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing

55.

Machine and method for forming articles

      
Application Number 16861490
Grant Number 11014279
Status In Force
Filing Date 2020-04-29
First Publication Date 2020-08-13
Grant Date 2021-05-25
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.

IPC Classes  ?

  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 43/20 - Making multilayered or multicoloured articles
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29L 9/00 - Layered products
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns

56.

Systems and methods for printing components using additive manufacturing

      
Application Number 16856457
Grant Number 10981330
Status In Force
Filing Date 2020-04-23
First Publication Date 2020-08-06
Grant Date 2021-04-20
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Vote, Nicolas C.

Abstract

A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.

IPC Classes  ?

  • G05B 19/41 - Numerical control (NC), i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by interpolation, e.g. the computation of intermediate points between programmed end points to define the path to be followed and the rate of travel along that path
  • B29C 64/227 - Driving means
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • G05B 19/414 - Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

57.

Print head for additive manufacturing

      
Application Number 16240101
Grant Number 10723074
Status In Force
Filing Date 2019-01-04
First Publication Date 2020-07-09
Grant Date 2020-07-28
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, John
  • Vaal, Scott G.

Abstract

An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/141 - Processes of additive manufacturing using only solid materials
  • B29C 64/218 - Rollers
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/227 - Driving means
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing

58.

Systems and methods for printing components using additive manufacturing

      
Application Number 16186053
Grant Number 10668664
Status In Force
Filing Date 2018-11-09
First Publication Date 2020-05-14
Grant Date 2020-06-02
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Vote, Nicolas C.

Abstract

A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the plurality of sections to manufacture the part.

IPC Classes  ?

  • B29C 64/227 - Driving means
  • G05B 19/41 - Numerical control (NC), i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by interpolation, e.g. the computation of intermediate points between programmed end points to define the path to be followed and the rate of travel along that path
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • G05B 19/414 - Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing

59.

Methods and apparatus for compensating for material distortion during additive manufacturing

      
Application Number 16677194
Grant Number 10800093
Status In Force
Filing Date 2019-11-07
First Publication Date 2020-05-07
Grant Date 2020-10-13
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

60.

Apparatus and methods for additive manufacturing at ambient temperature

      
Application Number 16677280
Grant Number 10889058
Status In Force
Filing Date 2019-11-07
First Publication Date 2020-03-19
Grant Date 2021-01-12
Owner Thermwood Corporation (USA)
Inventor Vaal, Scott G.

Abstract

An exemplary additive manufacturing system may include an extruder having an opening dimensioned to receive a material. The extruder also may have a barrel and a screw within the barrel. The screw may have a diameter ranging between about 20 mm and about 150 mm and the barrel extends along a longitudinal axis. The system may include one or more heaters positioned along at least a portion of the barrel. As the material passes through the barrel, the one or more heaters may at least partially melt the material. The system may further include a gear pump in fluid communication with the barrel for receiving the at least partially melted material. Additionally, the system may include a nozzle in fluid communication with the gear pump for depositing the at least partially melted material. The system also may include a vertical worktable.

IPC Classes  ?

  • B29C 64/205 - Means for applying layers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor

61.

Methods and apparatus for compressing material during additive manufacturing

      
Application Number 16572897
Grant Number 10744709
Status In Force
Filing Date 2019-09-17
First Publication Date 2020-02-27
Grant Date 2020-08-18
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B29C 64/218 - Rollers
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

62.

Apparatus and methods for fabricating components

      
Application Number 16661267
Grant Number 10723116
Status In Force
Filing Date 2019-10-23
First Publication Date 2020-02-20
Grant Date 2020-07-28
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth

Abstract

An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

IPC Classes  ?

  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29K 101/12 - Thermoplastic materials
  • B29C 64/245 - Platforms or substrates
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

63.

Methods and apparatus for compensating for thermal expansion during additive manufacturing

      
Application Number 16572953
Grant Number 10766244
Status In Force
Filing Date 2019-09-17
First Publication Date 2020-01-09
Grant Date 2020-09-08
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.

IPC Classes  ?

  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B26D 5/00 - Arrangements for operating and controlling machines or devices for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
  • B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • G01B 11/00 - Measuring arrangements characterised by the use of optical techniques
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
  • B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
  • B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/141 - Processes of additive manufacturing using only solid materials
  • B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
  • G01B 5/00 - Measuring arrangements characterised by the use of mechanical techniques
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29L 31/00 - Other particular articles
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles

64.

Additive manufacturing apparatus

      
Application Number 16002698
Grant Number 10532512
Status In Force
Filing Date 2018-06-07
First Publication Date 2019-12-12
Grant Date 2020-01-14
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.

Abstract

An additive manufacturing system may include an extruder. The extruder may include a barrel having a bore. Additionally, the extruder may include an extruder screw at least partially received within the bore of the barrel. The additive manufacturing system also may include a gear pump fluidly coupled to the bore of the barrel. The extruder screw may extend at least partially into the gear pump.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/343 - Metering
  • B29C 48/375 - Plasticisers, homogenisers or feeders comprising two or more stages
  • B29C 48/63 - Screws having sections without mixing elements or threads, i.e. having cylinder shaped sections
  • B29C 48/54 - Screws with additional forward-feeding elements
  • B29C 48/37 - Gear pumps
  • B29C 48/585 - Screws provided with gears interacting with the flow

65.

Methods and apparatus for processing and dispensing material during additive manufacturing

      
Application Number 16455877
Grant Number 10688719
Status In Force
Filing Date 2019-06-28
First Publication Date 2019-10-24
Grant Date 2020-06-23
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vote, Nicolas
  • Gaesser, Robert
  • Smiddy, Brian S.
  • Vaal, Scott G.

Abstract

A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing

66.

Apparatus and methods for fabricating components

      
Application Number 16415333
Grant Number 10486413
Status In Force
Filing Date 2019-05-17
First Publication Date 2019-09-05
Grant Date 2019-11-26
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth

Abstract

An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

IPC Classes  ?

  • B29C 64/218 - Rollers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29K 101/12 - Thermoplastic materials
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

67.

Machine and method for forming articles

      
Application Number 16403079
Grant Number 10668657
Status In Force
Filing Date 2019-05-03
First Publication Date 2019-08-22
Grant Date 2020-06-02
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 43/20 - Making multilayered or multicoloured articles
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29L 9/00 - Layered products
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns

68.

Methods and apparatus for thermal compensation during additive manufacturing

      
Application Number 16274041
Grant Number 10632683
Status In Force
Filing Date 2019-02-12
First Publication Date 2019-08-15
Grant Date 2020-04-28
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A method for thermal compensation during an additive manufacturing process. In some aspects, the method may include receiving, at a CNC machine, information relating to a material used in the additive manufacturing process, wherein the received information includes at least a Coefficient for Thermal Expansion (CTE) for the material. The method may further include modifying a distance of travel for a first pre-programmed tool path based on at least the Coefficient for Thermal Expansion (CTE).

IPC Classes  ?

  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • G06F 17/50 - Computer-aided design
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B33Y 10/00 - Processes of additive manufacturing
  • B29K 101/12 - Thermoplastic materials

69.

Apparatus and methods for additive manufacturing at ambient temperature

      
Application Number 15805451
Grant Number 10500788
Status In Force
Filing Date 2017-11-07
First Publication Date 2019-05-09
Grant Date 2019-12-10
Owner Thermwood Corporation (USA)
Inventor Vaal, Scott G.

Abstract

An exemplary additive manufacturing system may include an extruder having an opening dimensioned to receive a material. The extruder also may have a barrel and a screw within the barrel. The screw may have a diameter ranging between about 20 mm and about 150 mm and the barrel extends along a longitudinal axis. The system may include one or more heaters positioned along at least a portion of the barrel. As the material passes through the barrel, the one or more heaters may at least partially melt the material. The system may further include a gear pump in fluid communication with the barrel for receiving the at least partially melted material. Additionally, the system may include a nozzle in fluid communication with the gear pump for depositing the at least partially melted material. The system also may include a vertical worktable.

IPC Classes  ?

  • B29C 64/205 - Means for applying layers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/30 - Auxiliary operations or equipment

70.

Methods and apparatus for thermal compensation during additive manufacturing

      
Application Number 15896372
Grant Number 10245788
Status In Force
Filing Date 2018-02-14
First Publication Date 2019-04-02
Grant Date 2019-04-02
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A method for thermal compensation during an additive manufacturing process. In some aspects, the method may include receiving, at a CNC machine, information relating to a material used in the additive manufacturing process, wherein the received information includes at least a Coefficient for Thermal Expansion (CTE) for the material. The method may further include modifying a distance of travel for a first pre-programmed tool path based on at least the Coefficient for Thermal Expansion (CTE).

IPC Classes  ?

  • B29C 65/00 - Joining of preformed parts; Apparatus therefor
  • B29C 65/02 - Joining of preformed parts; Apparatus therefor by heating, with or without pressure
  • B32B 37/00 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B 38/00 - Ancillary operations in connection with laminating processes
  • B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
  • B32B 38/14 - Printing or colouring
  • C08J 5/00 - Manufacture of articles or shaped materials containing macromolecular substances
  • B05C 5/02 - Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work from an outlet device in contact, or almost in contact, with the work
  • B32B 41/00 - Arrangements for controlling or monitoring lamination processes; Safety arrangements
  • B65C 9/40 - Controls; Safety devices
  • G05G 15/00 - Mechanical devices for initiating a movement automatically due to a specific cause
  • B29D 30/28 - Rolling-down or pressing-down the layers in the building process
  • B32B 41/02 - Safety arrangements
  • B29C 65/78 - Means for handling the parts to be joined, e.g. for making containers or hollow articles
  • B65C 9/00 - LABELLING OR TAGGING MACHINES, APPARATUS, OR PROCESSES - Details of labelling machines or apparatus
  • B44B 5/02 - Dies; Accessories
  • B65C 9/46 - Applying date marks, code marks, or the like, to the label during labelling
  • B29B 15/00 - Pretreatment of the material to be shaped, not covered by groups
  • G06F 19/00 - Digital computing or data processing equipment or methods, specially adapted for specific applications (specially adapted for specific functions G06F 17/00;data processing systems or methods specially adapted for administrative, commercial, financial, managerial, supervisory or forecasting purposes G06Q;healthcare informatics G16H)
  • B29C 45/76 - Measuring, controlling or regulating
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 101/12 - Thermoplastic materials

71.

Apparatus and methods for compressing material during additive manufacturing

      
Application Number 15703634
Grant Number 10786946
Status In Force
Filing Date 2017-09-13
First Publication Date 2019-03-14
Grant Date 2020-09-29
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Smiddy, Brian S.

Abstract

Embodiments of the present disclosure are drawn to an additive manufacturing system, which may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. An applicator head may surround at least a portion of a proximal region of the nozzle. The applicator head may include a housing, a cooling inlet for receiving a coolant into the housing, a cooling outlet configured to allow the coolant to exit the housing, and an air inlet. A roller may be mounted on the applicator head to one side of the outlet of the nozzle. The roller may include an air outlet, wherein a flow path connects the air inlet and the air outlet so that air enters the air inlet and exits the air outlet. The roller may also include a plurality of holes located on an external surface of the roller.

IPC Classes  ?

  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/218 - Rollers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/245 - Platforms or substrates
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 101/12 - Thermoplastic materials

72.

Apparatus and method for printing large thermoplastic parts during additive manufacturing

      
Application Number 15703558
Grant Number 10933586
Status In Force
Filing Date 2017-09-13
First Publication Date 2019-03-14
Grant Date 2021-03-02
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.
  • Smiddy, Brian S.
  • Fuquay, Jonathan I.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder, the extruder having an opening dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle in fluid communication with the gear pump for depositing the at least partially melted material.

IPC Classes  ?

  • B29C 64/295 - Heating elements
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/241 - Driving means for rotary motion
  • B29C 48/285 - Feeding the extrusion material to the extruder
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/205 - Means for applying layers
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/227 - Driving means
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/218 - Rollers
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/25 - Housings, e.g. machine housings
  • B29C 48/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor

73.

Methods for compensating for thermal expansion during additive manufacturing

      
Application Number 15804565
Grant Number 10457036
Status In Force
Filing Date 2017-11-06
First Publication Date 2019-01-03
Grant Date 2019-10-29
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.

IPC Classes  ?

  • B29C 37/02 - Deburring or deflashing
  • G01B 11/16 - Measuring arrangements characterised by the use of optical techniques for measuring the deformation in a solid, e.g. optical strain gauge
  • G01N 25/16 - Investigating or analysing materials by the use of thermal means by investigating thermal coefficient of expansion
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B26D 5/00 - Arrangements for operating and controlling machines or devices for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
  • B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • G01B 11/00 - Measuring arrangements characterised by the use of optical techniques
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/147 - Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
  • B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
  • B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/141 - Processes of additive manufacturing using only solid materials
  • B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
  • G01B 5/00 - Measuring arrangements characterised by the use of mechanical techniques
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29L 31/00 - Other particular articles
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles

74.

Compression roller design and method for additive manufacturing

      
Application Number 15950724
Grant Number 10105894
Status In Force
Filing Date 2018-04-11
First Publication Date 2018-10-23
Grant Date 2018-10-23
Owner Thermwood Corporation (USA)
Inventor Smiddy, Brian S.

Abstract

An additive manufacturing system may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. The system also may include an applicator head surrounding at least a portion of the nozzle. Additionally, a roller may be mounted on the applicator head and rotatable about an axle. A coolant circuit may extend through at least a portion of the applicator head and through a lumen of the axle.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 35/16 - Cooling
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
  • B29K 105/06 - Condition, form or state of moulded material containing reinforcements, fillers or inserts

75.

Methods and apparatus for controlling an applicator head during additive manufacturing

      
Application Number 15435416
Grant Number 10549477
Status In Force
Filing Date 2017-02-17
First Publication Date 2018-08-23
Grant Date 2020-02-04
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vote, Nicolas

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include determining x and y coordinates for a tool path of an additive manufacturing machine, and calculating an angle of the tool path. The method may also include determining a position of a compression roller relative to the angle of the tool path, and moving the compression roller to position the compression roller relative to the angle of the tool path.

IPC Classes  ?

  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 10/00 - Processes of additive manufacturing

76.

Methods and apparatus for compressing material during additive manufacturing

      
Application Number 15435408
Grant Number 10449710
Status In Force
Filing Date 2017-02-17
First Publication Date 2018-08-23
Grant Date 2019-10-22
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/218 - Rollers
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

77.

Methods and apparatus for compensating for material distortion during additive manufacturing

      
Application Number 15435431
Grant Number 10500785
Status In Force
Filing Date 2017-02-17
First Publication Date 2018-08-23
Grant Date 2019-12-10
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vaal, Scott G.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.

IPC Classes  ?

  • B29C 47/36 - Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

78.

Machine and method for forming articles

      
Application Number 15950778
Grant Number 10286588
Status In Force
Filing Date 2018-04-11
First Publication Date 2018-08-16
Grant Date 2019-05-14
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 47/06 - Multilayered articles
  • B29C 43/20 - Making multilayered or multicoloured articles
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29L 9/00 - Layered products
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns

79.

Apparatus and method for printing long composite thermoplastic parts on a dual gantry machine during additive manufacturing

      
Application Number 15921372
Grant Number 10065361
Status In Force
Filing Date 2018-03-14
First Publication Date 2018-08-09
Grant Date 2018-09-04
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, Jonathan I.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary apparatus for fabricating components via additive manufacturing may include a programmable CNC machine. The CNC machine may comprise a first worktable extending in a first plane and a second worktable extending in a second plane, wherein the second plane is oriented at an angle relative to the first plane. At least one conveyor belt may be operably coupled to the first worktable. A printing gantry may be displaceable along a first axis of the CNC machine. The CNC machine may also comprise an applicator having a nozzle configured to deposit material on the second worktable.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
  • B21D 51/10 - Making hollow objects characterised by the structure of the objects conically or cylindrically shaped objects
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 70/54 - Component parts, details or accessories; Auxiliary operations
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 70/16 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

80.

Apparatus and method for printing long composite thermoplastic parts on a dual gantry machine during additive manufacturing

      
Application Number 15621469
Grant Number 10071525
Status In Force
Filing Date 2017-06-13
First Publication Date 2018-08-09
Grant Date 2018-09-11
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian S.
  • Fuquay, Jonathan I.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary apparatus for fabricating components via additive manufacturing may include a programmable CNC machine. The CNC machine may comprise a first worktable extending in a first plane and a second worktable extending in a second plane, wherein the second plane is oriented at an angle relative to the first plane. At least one conveyor belt may be operably coupled to the first worktable. A printing gantry may be displaceable along a first axis of the CNC machine. The CNC machine may also comprise an applicator having a nozzle configured to deposit material on the second worktable.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 70/16 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • B29C 70/54 - Component parts, details or accessories; Auxiliary operations
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns

81.

Methods of adjusting layer print speed on 3D printing machines

      
Application Number 15934573
Grant Number 10037022
Status In Force
Filing Date 2018-03-23
First Publication Date 2018-07-31
Grant Date 2018-07-31
Owner Thermwood Corporation (USA)
Inventor
  • Vote, Nicolas
  • Vaal, Scott G.

Abstract

A method for adjusting print speed during an additive manufacturing process may include receiving at an additive manufacturing machine, information including at least a current layer print speed. The method may further include determining a current layer print time based on at least the current layer print speed and adjusting the current layer print speed to an adjusted current layer print speed based on at least the current layer print time and a minimum layer cooling time. Further, the method may include printing a layer of a part at the adjusted current layer print speed.

IPC Classes  ?

  • G05B 19/25 - Numerical control (NC), i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path using an incremental digital measuring device for continuous-path control
  • G05B 19/416 - Numerical control (NC), i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control of velocity, acceleration or deceleration
  • G05B 19/414 - Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing

82.

Compression roller design and method for additive manufacturing

      
Application Number 15805496
Grant Number 09969122
Status In Force
Filing Date 2017-11-07
First Publication Date 2018-05-15
Grant Date 2018-05-15
Owner THERMWOOD CORPORATION (USA)
Inventor Smiddy, Brian S.

Abstract

An additive manufacturing system may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. The system also may include an applicator head surrounding at least a portion of the nozzle. Additionally, a roller may be mounted on the applicator head and rotatable about an axle. A coolant circuit may extend through at least a portion of the applicator head and through a lumen of the axle.

IPC Classes  ?

  • B29C 64/209 - Heads; Nozzles
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B29C 35/16 - Cooling
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29K 105/06 - Condition, form or state of moulded material containing reinforcements, fillers or inserts
  • B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material

83.

Methods and apparatus for processing and dispensing material during additive manufacturing

      
Application Number 15253290
Grant Number 10377124
Status In Force
Filing Date 2016-08-31
First Publication Date 2018-03-01
Grant Date 2019-08-13
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Vote, Nicolas
  • Gaesser, Robert
  • Vaal, Scott G.

Abstract

An additive manufacturing method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, the nozzle being configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes. In one embodiment, the method includes actuating an extruder to form a flowable material, delivering the flowable material to a pump, sensing a pressure of the flowable material, and adjusting at least one of a speed of the extruder and a speed of the pump based on at least one of the sensed pressure and a rate of translation of the nozzle along one or more of the first, second, and third axes.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29K 101/12 - Thermoplastic materials
  • B29K 105/00 - Condition, form or state of moulded material

84.

Method of forming three-dimensional decorative items

      
Application Number 15226471
Grant Number 09956657
Status In Force
Filing Date 2016-08-02
First Publication Date 2018-02-08
Grant Date 2018-05-01
Owner THERMWOOD CORPORATION (USA)
Inventor Susnjara, Kenneth J.

Abstract

Aspects of the present disclosure relate to methods for fabricating components, for example, 3D decorative items. In an embodiment, a method including positioning a spoil board on a worktable of a computer numeric control (CNC) machine; operating the CNC machine in a first mode to create an outline in the spoil board; positioning a first workpiece on the spoil board and over at least a portion of the outline; and operating the CNC machine in a second mode to cut into a portion of the first workpiece.

IPC Classes  ?

  • B23Q 3/08 - Work-clamping means other than mechanically-actuated
  • B23C 1/06 - Milling machines not designed for particular work or special operations with one vertical working-spindle
  • B23C 1/00 - Milling machines not designed for particular work or special operations
  • B27M 3/12 - Manufacture or reconditioning of specific semi-finished or finished articles of railings, stairs, stair stringers, ladders, or parts thereof
  • B23Q 35/04 - Control systems or devices for copying directly from a pattern or a master model; Devices for use in copying manually using a feeler or the like travelling along the outline of the pattern, model or drawing; Feelers, patterns, or models therefor

85.

Methods and apparatus for compensating for thermal expansion during additive manufacturing

      
Application Number 15636789
Grant Number 09833986
Status In Force
Filing Date 2017-06-29
First Publication Date 2017-12-05
Grant Date 2017-12-05
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.

IPC Classes  ?

  • B29C 37/02 - Deburring or deflashing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B26D 5/00 - Arrangements for operating and controlling machines or devices for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
  • B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • G01B 11/00 - Measuring arrangements characterised by the use of optical techniques
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material

86.

Machine for forming thermoplastic articles and device utilized in the production thereof

      
Application Number 15626579
Grant Number 10059051
Status In Force
Filing Date 2017-06-19
First Publication Date 2017-11-16
Grant Date 2018-08-28
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An assembly mountable on a machine including a gantry displaceable along an x-axis, a carriage mounted on such gantry displaceable along the y-axis, provided with means for extruding a beam of molten thermoplastic material, a tool carrier mounted on such carriage displaceable along a z-axis, a tool holder mounted on such tool carrier displaceable about a z-axis, a tool support shaft provided with an axis disposed in an x-y plane journalled in such tool holder and rotatable about the axis thereof, a dispenser conduit mounted on such shaft, perpendicular to such shaft axis, means on such dispenser conduit for ejection of a beam of molten thermoplastic material and a flexible hose with a first end supported on such carrier forming a rotary union with such material extrusion means, and a second end communicating with an inlet of such dispenser conduit.

IPC Classes  ?

  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
  • B29C 47/08 - Component parts, details or accessories; Auxiliary operations
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B29K 101/12 - Thermoplastic materials
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor

87.

Additive manufacturing apparatus

      
Application Number 15626405
Grant Number 10065360
Status In Force
Filing Date 2017-06-19
First Publication Date 2017-11-16
Grant Date 2018-09-04
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian Scott

Abstract

A CNC machine including a worktable displaceable along y-axis, a gantry disposed along an x-axis, either fixed or displaceable along the y-axis, a carriage on such gantry displaceable along the x-axis and including a thermoplastic material extrusion conduit, a tool carrier mounted on such carriage displaceable along a z-axis, a dispersion conduit mounted on such tool carrier accommodating an applicator, means mounted on such applicator for extruding a molten bead of a thermoplastic material, a flexible hose interconnecting such molten material forming means and such applicator, a plurality of servomotors for linearly or rotationally displacing such components along or about such axes and a computer for controlling such component displacements.

IPC Classes  ?

  • B29C 64/227 - Driving means
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B25J 9/02 - Programme-controlled manipulators characterised by movement of the arms, e.g. cartesian co-ordinate type
  • B25J 19/00 - Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
  • B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
  • B25J 5/04 - Manipulators mounted on wheels or on carriages travelling along a guideway wherein the guideway is also moved, e.g. travelling crane bridge type
  • B25J 11/00 - Manipulators not otherwise provided for
  • B25J 15/00 - Gripping heads
  • B25J 15/04 - Gripping heads with provision for the remote detachment or exchange of the head or parts thereof
  • B29C 47/08 - Component parts, details or accessories; Auxiliary operations
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29K 101/12 - Thermoplastic materials
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B23Q 5/02 - Driving main working members
  • B29K 105/00 - Condition, form or state of moulded material
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/321 - Feeding
  • B23Q 3/155 - Arrangements for automatic insertion or removal of tools

88.

Methods of securing an initial layer during additive manufacturing of thermoplastic material

      
Application Number 15373660
Grant Number 10569523
Status In Force
Filing Date 2016-12-09
First Publication Date 2017-10-05
Grant Date 2020-02-25
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth
  • Vaal, Scott

Abstract

In one embodiment, an additive manufacturing method including the steps of positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed; depositing a first plurality of layers of a flowable material on at least some of the plurality of pellets; and depositing a second plurality of layers of the flowable material on the first plurality of layers.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/245 - Platforms or substrates
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 101/12 - Thermoplastic materials
  • B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles

89.

Methods of securing an initial layer during additive manufacturing of thermoplastic material

      
Application Number 15090819
Grant Number 10569521
Status In Force
Filing Date 2016-04-05
First Publication Date 2017-10-05
Grant Date 2020-02-25
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth
  • Vaal, Scott

Abstract

In one embodiment, an additive manufacturing method including the steps of positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed; and depositing a flowable material on at least some of the plurality of pellets.

IPC Classes  ?

  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/30 - Auxiliary operations or equipment
  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29K 101/12 - Thermoplastic materials
  • B29L 9/00 - Layered products

90.

Apparatus and methods for fabricating components

      
Application Number 15062602
Grant Number 10336050
Status In Force
Filing Date 2016-03-07
First Publication Date 2017-09-07
Grant Date 2019-07-02
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth

Abstract

An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

IPC Classes  ?

  • B29C 64/218 - Rollers
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B29K 101/12 - Thermoplastic materials

91.

Machine and method for forming articles

      
Application Number 14980818
Grant Number 10611073
Status In Force
Filing Date 2015-12-28
First Publication Date 2017-06-29
Grant Date 2020-04-07
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 48/18 - Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C 43/20 - Making multilayered or multicoloured articles
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29L 9/00 - Layered products
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns

92.

System for confining particulate residue in a machining operation

      
Application Number 14823406
Grant Number 09527183
Status In Force
Filing Date 2015-08-11
First Publication Date 2016-12-27
Grant Date 2016-12-27
Owner Thermwood Corporation (USA)
Inventor Hardesty, Michael P.

Abstract

An assembly for the removal of particulate residue generated by a CNC machine including a first means mounted on a gantry thereof for directing a stream of air downwardly toward a worktable thereof and at a degree toward a tool holder thereof effective to form an air current across a forwardly disposed opening of such gantry and entrain particulate residue, a second means mounted on such gantry rearwardly of such first means for directing a stream of air downwardly toward such worktable and to a degree toward such tool holder effective to form an air curtain across a rearwardly disposed opening of such gantry and entrain particulate residue and means mounted on such gantry for exhausting air entrained with such particulate residue from within such gantry between such air curtain.

IPC Classes  ?

  • B23Q 11/00 - Accessories fitted to machine tools for keeping tools or parts of the machine in good working condition or for cooling work; Safety devices specially combined with or arranged in, or specially adapted for use in connection with, machine tools
  • B23C 1/00 - Milling machines not designed for particular work or special operations

93.

Additive manufacturing apparatus

      
Application Number 14701631
Grant Number 09713902
Status In Force
Filing Date 2015-05-01
First Publication Date 2016-11-03
Grant Date 2017-07-25
Owner Thermwood Corporation (USA)
Inventor
  • Susnjara, Kenneth J.
  • Smiddy, Brian Scott

Abstract

A CNC machine including a worktable displaceable along a y-axis, a gantry disposed along an x-axis, either fixed or displaceable along the y-axis, a carriage on such gantry displaceable along the x-axis and including a thermoplastic material extrusion conduit, a tool carrier mounted on such carriage displaceable along a z-axis, a dispersion conduit mounted on such tool carrier accommodating an applicator, means mounted on such applicator for extruding a molten bead of a thermoplastic material, a flexible hose interconnecting such molten material forming means and such applicator, a plurality of servomotors for linearly or rotationally displacing such components along or about such axes and a computer for controlling such component displacements.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B25J 9/02 - Programme-controlled manipulators characterised by movement of the arms, e.g. cartesian co-ordinate type
  • B25J 19/00 - Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
  • B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
  • B25J 5/04 - Manipulators mounted on wheels or on carriages travelling along a guideway wherein the guideway is also moved, e.g. travelling crane bridge type
  • B25J 11/00 - Manipulators not otherwise provided for
  • B25J 15/00 - Gripping heads
  • B25J 15/04 - Gripping heads with provision for the remote detachment or exchange of the head or parts thereof
  • B29K 101/12 - Thermoplastic materials
  • B29K 105/00 - Condition, form or state of moulded material
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B23Q 5/02 - Driving main working members

94.

Machine for forming thermoplastic articles and device utilized in the production thereof

      
Application Number 14678286
Grant Number 09707721
Status In Force
Filing Date 2015-04-03
First Publication Date 2016-10-06
Grant Date 2017-07-18
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An assembly mountable on a machine including a gantry displaceable along an x-axis, a carriage mounted on such gantry displaceable along the y-axis, provided with means for extruding a beam of molten thermoplastic material, a tool carrier mounted on such carriage displaceable along a z-axis, a tool holder mounted on such tool carrier displaceable about a z-axis, a tool support shaft provided with an axis disposed in an x-y plane journalled in such tool holder and rotatable about the axis thereof, a dispenser conduit mounted on such shaft, perpendicular to such shaft axis, means on such dispenser conduit for ejection of a beam of molten thermoplastic material and a flexible hose with a first end supported on such carrier forming a rotary union with such material extrusion means, and a second end communicating with an inlet of such dispenser conduit.

IPC Classes  ?

  • B29C 67/00 - Shaping techniques not covered by groups , or
  • B29C 47/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor (extrusion blow-moulding B29C 49/04)
  • B29C 47/08 - Component parts, details or accessories; Auxiliary operations
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B29K 101/12 - Thermoplastic materials

95.

CNC machine assembly

      
Application Number 14575650
Grant Number 09808950
Status In Force
Filing Date 2014-12-18
First Publication Date 2016-06-23
Grant Date 2017-11-07
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An assembly for producing cabinet doors including a CNC machine provided with a porous worktable, means for positioning workpieces thereon, means for applying a vacuum to such porous worktable for adhering such workpieces thereto and means for machining such workpieces adhered to such worktable; and means for thermally deforming a thermally pliable foil to laminate such workpiece.

IPC Classes  ?

  • B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
  • A47B 96/20 - Furniture panels or like furniture elements
  • B32B 38/04 - Punching, slitting or perforating
  • B26D 7/01 - Means for holding or positioning work
  • B32B 38/00 - Ancillary operations in connection with laminating processes
  • B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
  • B32B 38/10 - Removing layers, or parts of layers, mechanically or chemically
  • B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
  • B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
  • B32B 38/18 - Handling of layers or the laminate

96.

System for managing tool life on CNC machines

      
Application Number 14559008
Grant Number 09753451
Status In Force
Filing Date 2014-12-03
First Publication Date 2016-06-09
Grant Date 2017-09-05
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A system for managing the longevity of tools of a programmable CNC machine including means for inputting into the machine control a designation of a tool for use therein, means for recording the time of usage of such tool, means for computing the cumulative time of usage of such tool over a lifetime of usage thereof, means for computing the average time of usage of such tool and means for signaling the usage of such tool for a selected percentage of such average time.

IPC Classes  ?

97.

Method of installing a drawer in a cabinet

      
Application Number 14276476
Grant Number 09693629
Status In Force
Filing Date 2014-05-13
First Publication Date 2015-11-19
Grant Date 2017-07-04
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A method of installing a drawer in a compartment of a structure including inserting a set of pins in pin holes provide in spaced walls of such compartments; positioning a drawer support assembly including a track member and a cooperable slide member on each side wall with each track member seated on a set of pins and connected to a side wall, and a slide member displaceable relative to said track member; displacing bending ends of the slide members equal distances beyond such compartment; inserting the drawer between such extended slide members, seated in such pins; fasting leading ends of the slide members to the drawer; incrementally further withdrawing such drawer from the compartment; and fastening the side members to adjacent side wall of the drawer upon having further drawn the drawer incrementally.

IPC Classes  ?

  • A47B 88/00 - Drawers for tables, cabinets or like furniture; Guides for drawers
  • A47B 88/423 - Fastening devices for slides or guides
  • A47B 88/43 - Fastening devices for slides or guides at cabinet side

98.

System for positioning a workpiece on a machine worktable

      
Application Number 14275141
Grant Number 09440321
Status In Force
Filing Date 2014-05-12
First Publication Date 2015-11-12
Grant Date 2016-09-13
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A system for positioning a workpiece on the worktable of a machine including at least one stop device mounted on such machine, including a first component provided with a fluid passageway having an inlet connected to a fluid pressure line including a pressure sensor, and an outlet disposed in an abutment surface thereof, and a second component displaceable relative to such abutment surface, into and out of obstructive relation with such outlet, affecting the pressure in such supply line and correspondingly effecting a hold down of a workpiece positioned on such worktable.

IPC Classes  ?

  • B23Q 16/00 - Equipment for precise positioning of tool or work into particular locations not otherwise provided for
  • B23Q 3/18 - Devices holding, supporting, or positioning, work or tools, of a kind normally removable from the machine for positioning only
  • B23Q 3/08 - Work-clamping means other than mechanically-actuated
  • B27C 9/00 - Multi-purpose machines; Universal machines; Equipment therefor

99.

Apparatus for inverting large panels

      
Application Number 14254081
Grant Number 09527178
Status In Force
Filing Date 2014-04-16
First Publication Date 2015-10-22
Grant Date 2016-12-27
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

An apparatus for inverting a panel including a base assembly, an elongated support assembly mounted on the base assembly, a carriage assembly mounted on the support assembly displaceable along the length thereof, means for displacing the carriage assembly along the length of the support assembly, an elongated beam assembly provided with means for detachably securing a panel, pivotally connected to the carriage assembly and means for pivoting the beam assembly relative to the support assembly.

IPC Classes  ?

  • B65G 7/08 - Devices adapted to be interposed between loads and the ground or floor, e.g. crowbars with means for assisting conveyance of loads for tilting the loads
  • B23Q 7/00 - Arrangements for handling work specially combined with or arranged in, or specially adapted for use in connection with, machine tools, e.g. for conveying, loading, positioning, discharging, sorting
  • B27M 1/08 - Working of wood not provided for in subclasses , e.g. by stretching by multi-step processes

100.

Joint construction and method of making same

      
Application Number 14164950
Grant Number 09441662
Status In Force
Filing Date 2014-01-27
First Publication Date 2015-07-30
Grant Date 2016-09-13
Owner Thermwood Corporation (USA)
Inventor Susnjara, Kenneth J.

Abstract

A method of joining a first workpiece having a first surface and a second surface angularly disposed relative to such first surface, and a second workpiece having a surface disposable in abutting relation relative to the second surface of such first workpiece, comprising forming a recess in the first surface of such first workpiece, sloped toward and spaced from the second surface of such first workpiece, producing an end surface thereof disposed at an angle relative to a longitudinal centerline of such recess; forming a notched ledge on the end surface of such recess; positioning a threaded fastener in the sloped recess with a head portion thereof resting on a bottom surface of the recess and the threaded portion thereof disposed along the centerline with the end thereof resting on such ledge; disposing the surface of the second workpiece in abutting relation with the second surface of the first workpiece; and threading the threaded fastener along the longitudinal centerline of such recess, through such abutting surfaces of such workpieces to join such workpieces together.

IPC Classes  ?

  • B25G 3/00 - Attaching handles to the implements
  • F16B 2/14 - Clamps, i.e. with gripping action effected by positive means other than the inherent resistance to deformation of the material of the fastening using wedges
  • F16B 35/04 - Screw-bolts; Stay bolts; Screw-threaded studs; Screws; Set screws with specially-shaped head or shaft in order to fix the bolt on or in an object
  • E04B 1/26 - Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of wood
  • F16B 25/00 - Screws that form threads in the body into which they are screwed, e.g. wood screws, self-tapping screws
  • B27C 3/06 - Drilling machines or devices for making dowel holes
  • F16B 5/02 - Joining sheets or plates to one another or to strips or bars parallel to them by means of fastening members using screw-thread
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