Desktop Metal, Inc.

United States of America

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B33Y 10/00 - Processes of additive manufacturing 94
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 70
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes 59
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor 43
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling 39
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1.

TECHNIQUES FOR DEPOWDERING ADDITIVELY FABRICATED PARTS THROUGH VIBRATORY MOTION AND RELATED SYSTEMS AND METHODS

      
Application Number 18493348
Status Pending
Filing Date 2023-10-24
First Publication Date 2024-06-06
Owner Desktop Metal, Inc. (USA)
Inventor
  • Go, Jamison
  • Shydo, Jr., Robert Michael
  • Sachs, Emanuel M.
  • Santorella, Michael
  • Zero, Midnight
  • Myerberg, Jonah Samuel
  • Gabay, Joseph
  • Von Loesecke, Jeffrey
  • Mccalmont, Alexander K.

Abstract

Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts through vibration of the powder, the parts, and/or structures mechanically connected to the powder and/or parts. For instance, the application of vibration may dislodge, aerate and/or otherwise increase the flowability of regions of the powder, thereby making it easier to remove the powder with a suitable means. Techniques for depowdering through vibration may be automated, thereby mitigating challenges associated with manual depowdering operations.

IPC Classes  ?

  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • 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

2.

TECHNIQUES FOR DEPOWDERING ADDITIVELY FABRICATED PARTS VIA GAS FLOW AND RELATED SYSTEMS AND METHODS

      
Application Number 18441951
Status Pending
Filing Date 2024-02-14
First Publication Date 2024-06-06
Owner Desktop Metal, Inc. (USA)
Inventor
  • Go, Jamison
  • Santorella, Michael
  • Myerberg, Jonah Samuel
  • Mccambridge, Matthew
  • Legendre, Alexander
  • Gabay, Joseph
  • Nick, Robert J.
  • Goldblatt, Michael

Abstract

Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts by directing gas onto, or near to, the powder. While fragile green parts, such as green parts produced by binder jetting, may be fragile with respect to scraping or impacts, such parts may nonetheless be resistance to damage from directed gas, even if directed at a high pressure. Techniques for depowdering through directed application of gas may be automated, thereby mitigating challenges associated with manual depowdering operations.

IPC Classes  ?

  • B08B 5/02 - Cleaning by the force of jets, e.g. blowing-out cavities
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 3/10 - Sintering only
  • 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

3.

Powder Distribution System for Three-Dimensional Printer

      
Application Number 18210047
Status Pending
Filing Date 2023-06-14
First Publication Date 2024-05-23
Owner Desktop Metal, Inc. (USA)
Inventor
  • Flick, Jake
  • Mccoy, Michael John
  • Bolt, Joseph J.
  • Hydock, Alec
  • Inks, Travis Maxwell
  • Dugan, Anthony S.
  • Lizzi, Thomas

Abstract

The present invention relates to powder-layer three-dimensional printers (2) having a discrete supply hopper (340) and a recoater (20). The discrete supply hopper (340) is configured to transfer a build powder to the recoater (20) in a manner that enhances the uniformity of build powder layers that are dispensed from the recoater (20). In some embodiments, at least one of the discrete supply hopper and the powder hopper of the recoater is adapted to selectively contact the other, seal against the other, and/or have one partially inserted inside the other so as to diminish or prevent powder pluming during the transfer of build powder from the discrete supply hopper to the recoater.

IPC Classes  ?

  • 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
  • B07B 1/40 - Resonant vibration screens
  • B22F 12/52 - Hoppers
  • B22F 12/67 - Blades
  • B29C 64/205 - Means for applying layers
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/329 - Feeding using hoppers
  • B29C 64/35 - Cleaning
  • 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

4.

TECHNIQUES FOR DEPOWDERING ADDITIVELY FABRICATED PARTS THROUGH FLUID IMMERSION AND RELATED SYSTEMS AND METHODS

      
Application Number 18363441
Status Pending
Filing Date 2023-08-01
First Publication Date 2024-05-02
Owner Desktop Metal, Inc. (USA)
Inventor
  • Go, Jamison
  • Sachs, Daniel
  • Nick, Robert J.
  • Myerberg, Jonah Samuel
  • Goldblatt, Michael

Abstract

Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from additively fabricated parts through liquid immersion of the parts. Motion of the liquid, such as liquid currents, may dislodge or otherwise move powder away from additively fabricated parts to which it is adhered or otherwise proximate to. The liquid may also provide a vehicle to carry away powder from the additively fabricated parts. Removed powder may be filtered or otherwise separated from the liquid to allow recirculation of the liquid to the parts and/or to enable re-use of the powder in subsequent additive fabrication processes. Techniques for depowdering through liquid immersion may be automated, thereby mitigating challenges associated with manual depowdering operations.

IPC Classes  ?

  • B22F 3/24 - After-treatment of workpieces or articles
  • B08B 3/04 - Cleaning involving contact with liquid
  • B08B 3/10 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
  • B08B 3/12 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
  • B08B 3/14 - Removing waste, e.g. labels, from cleaning liquid
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

5.

Adaptive 3D Printing

      
Application Number 18209067
Status Pending
Filing Date 2023-06-13
First Publication Date 2024-03-14
Owner Desktop Metal, Inc. (USA)
Inventor
  • Chin, Ricardo
  • Gibson, Michael A.
  • Reeves, Blake Z.
  • Raghu, Shashank Holenarasipura

Abstract

Methods provide for fabricating objects through additive manufacturing in a manner that compensates for deformations introduced during post-print processing, such as sintering. An initial model may be divided into a plurality of segments, the initial model defining geometry of an object. For each of the segments, modified geometry may be calculated, where the modified geometry compensates for a predicted deformation. Print parameters can then be updated to incorporate the modified geometry, where the print parameters define geometry of the printed object (e.g., configuration settings of the printer, a tool path, an object model). The object may then be printed based on the updated print parameters.

IPC Classes  ?

  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 3/24 - After-treatment of workpieces or articles
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • G06F 30/17 - Mechanical parametric or variational design

6.

Shot Brush Depowdering

      
Application Number 18212658
Status Pending
Filing Date 2023-06-21
First Publication Date 2023-12-28
Owner Desktop Metal, Inc. (USA)
Inventor Myerberg, Jonah Samuel

Abstract

A method of de-powdering green parts manufactured via binder jetting additive manufacturing. First, a bulk de-powdering operation is conducted on the green part. Next, a fine de-powdering operation is conducted on the green part. The fine de-powdering operation includes disposing the green part within a bed of shot brush de-powdering media and agitating the bed of shot brush de-powdering media to remove from at least one surface of the green part an amount of build material powder.

IPC Classes  ?

  • B22F 10/68 - Cleaning or washing
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 12/86 - Serial processing with multiple devices grouped
  • 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

7.

ADDITIVE FABRICATION OF SINTERABLE METALLIC PARTS VIA APPLICATION OF DIRECTED ENERGY

      
Application Number 18193505
Status Pending
Filing Date 2023-03-30
First Publication Date 2023-11-30
Owner Desktop Metal, Inc. (USA)
Inventor
  • Myerberg, Jonah Samuel
  • Hart, Anastasios John

Abstract

According to some aspects, techniques are provided for fabricating sinterable metallic parts through the application of directed energy to a build material. In particular, applying energy to a build material comprising a polymer mixed with a metal powder may cause the polymer to form a cohesive structure with the metal powder. As a result, the polymer acts as a “glue” to produce a metallic green part without local melting of the metal. The green part may subsequently be sintered to remove the polymer and produce a fully dense metal part. Optionally, a step of debinding may also be performed prior to, or simultaneously with, sintering.

IPC Classes  ?

  • 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 64/264 - Arrangements for irradiation
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 1/102 - Metallic powder coated with organic material

8.

Compound Furnace

      
Application Number 18233217
Status Pending
Filing Date 2023-08-11
First Publication Date 2023-11-30
Owner Desktop Metal, Inc. (USA)
Inventor Woodard, Nathan

Abstract

A compound sintering furnace with managed contamination for debinding and sintering parts. An inner insulation layer is disposed within an outer insulation layer and has an internal hot face surrounding a work zone. A sealed housing surrounds the inner insulation layer and is composed of a refractory material capable of withstanding a service temperature greater than a debinding temperature and less than a sintering temperature. An outer heater system is configured to heat at least a portion of the sealed housing and externally heat the inner insulation layer to, in conjunction with an inner heater system, heat the work zone to the debinding temperature, and inhibit condensation of a binder within and upon the inner insulation layer during a debinding process. The inner heater system is configured to internally heat the inner insulation and heat the work zone to the sintering temperature.

IPC Classes  ?

  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B22F 3/10 - Sintering only
  • F27B 5/04 - Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated adapted for treating the charge in vacuum or special atmosphere
  • F27B 5/14 - Arrangements of heating devices

9.

METATHESIS POLYMERIZATION BINDERS FOR ADDITIVE MANUFACTURING

      
Application Number 18315021
Status Pending
Filing Date 2023-05-10
First Publication Date 2023-11-16
Owner Desktop Metal, Inc. (USA)
Inventor
  • Creran, Brian
  • Nick, Robert J.
  • Barbati, Alexander C.
  • Lund, Benjamin Robert

Abstract

Techniques are provided for fabricating parts via additive manufacturing by causing a component of a build material powder to contact a binder composition to thereby perform a metathesis chain-growth polymerization reaction (e.g., an olefin metathesis polymerization reaction such as ring-opening metathesis polymerization).

IPC Classes  ?

  • 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
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing

10.

MOLD LOCK REMEDIATION

      
Application Number 18218163
Status Pending
Filing Date 2023-07-05
First Publication Date 2023-11-09
Owner Desktop Metal, Inc. (USA)
Inventor
  • Chin, Ricardo
  • Reeves, Blake Z.

Abstract

Mold lock is remediated by performing a layer-by-layer, two-dimensional analysis to identify unconstrained removal paths for any support structure or material within each two-dimensional layer, and then ensuring that aligned draw paths are present for all adjacent layers, all as more specifically described herein. Where locking conditions are identified, a sequence of modification rules are then applied, such as by breaking support structures into multiple, independently removable pieces. By addressing mold lock as a series of interrelated two-dimensional geometric problems, and reserving three-dimensional remediation strategies for more challenging, complex mold lock conditions, substantial advantages can accrue in terms of computational speed and efficiency.

IPC Classes  ?

  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B28B 17/00 - SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER - Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
  • B28B 1/00 - Producing shaped articles from the material
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • H04N 1/409 - Edge or detail enhancement; Noise or error suppression
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B22F 10/20 - Direct sintering or melting
  • B22F 10/40 - Structures for supporting workpieces or articles during manufacture and removed afterwards
  • B22F 10/64 - Treatment of workpieces or articles after build-up by thermal means

11.

SYSTEMS AND METHODS FOR ADJUSTING A THREE-DIMENSIONAL (3D) MODEL DURING ADDITIVE MANUFACTURING

      
Application Number 18108639
Status Pending
Filing Date 2023-02-12
First Publication Date 2023-08-24
Owner Desktop Metal, Inc. (USA)
Inventor
  • Barbati, Alexander
  • Gibson, Michael
  • Hudelson, George
  • Mykulowycz, Nicholas
  • Kernan, Brian
  • Tuncer, Nihan

Abstract

Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

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]
  • 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 64/379 - Handling of additively manufactured objects, e.g. using robots

12.

SYSTEMS AND METHODS FOR MECHANICAL DISTORTION COMPENSATION

      
Application Number 18122610
Status Pending
Filing Date 2023-03-16
First Publication Date 2023-07-13
Owner Desktop Metal, Inc. (USA)
Inventor
  • Roberts, Andrew Fiske
  • Djanikian, Artyom

Abstract

The present invention is directed to systems and methods for automatically generating mechanical part designs and manufacturing specifications/instructions that account for geometric distortions that may occur during manufacturing or post-processing.

IPC Classes  ?

  • G06F 30/20 - Design optimisation, verification or simulation
  • G06F 30/17 - Mechanical parametric or variational design
  • G06T 17/20 - Wire-frame description, e.g. polygonalisation or tessellation

13.

Managing powder mobility in binder jetting for additive manufacturing

      
Application Number 17956207
Grant Number 11858210
Status In Force
Filing Date 2022-09-29
First Publication Date 2023-05-18
Grant Date 2024-01-02
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Emanuel Michael
  • Hudelson, George
  • Hoisington, Paul A.
  • Renner, Christopher Benjamin
  • Vaillancourt, Keith Roy
  • Moynihan, Edward Russell

Abstract

Devices, systems, and methods are directed to the use of vapor phase change in binder jetting processes for forming three-dimensional objects. In general, a vapor of a first fluid may be directed to a layer of a powder spread across a build volume. The vapor may condense to reduce mobility of the particles of the powder of the layer. For example, the condensing vapor may reduce the likelihood of particle ejection from the layer and, thus, may reduce the likelihood of clogging or otherwise degrading a printhead used to jet a second fluid (e.g., a binder) to the layer. Further, or instead, the condensing vapor may increase the density of the powder in the layer which, when repeated over a plurality of layers forming a three-dimensional object, may reduce the likelihood of slumping of the part during sintering.

IPC Classes  ?

  • 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/364 - Conditioning of environment
  • 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 64/209 - 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 64/30 - Auxiliary operations or equipment
  • 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
  • B28B 1/00 - Producing shaped articles from the material
  • B29C 64/371 - Conditioning of environment using an environment other than air, e.g. inert gas
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B22F 1/148 - Agglomerating
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 12/10 - Auxiliary heating means
  • B22F 12/84 - Parallel processing within single device
  • B22F 10/32 - Process control of the atmosphere, e.g. composition or pressure in a building chamber
  • B22F 12/53 - Nozzles
  • B22F 12/63 - Rollers
  • B22F 12/90 - Means for process control, e.g. cameras or sensors

14.

TECHNIQUES FOR DEPOWDERING ADDITIVELY FABRICATED PARTS VIA RAPID PRESSURE CHANGE AND RELATED SYSTEMS AND METHODS

      
Application Number 17976282
Status Pending
Filing Date 2022-10-28
First Publication Date 2023-05-18
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Emanuel M.
  • Zero, Midnight

Abstract

Techniques for depowdering additively fabricated parts are described in which powder is separated from parts by creating a large pressure differential between the powder and parts and a nearby location. The pressure differential may cause gas to quickly flow into and/or around the powder and parts, thereby producing a force against the powder and parts. Since the powder is generally much lighter than the parts, this force may be much more effective at moving the powder than moving the parts. As a result, the powder and parts may be separated from one another. The pressure differential may be created in various ways, such as by holding the parts and part in a chamber that is pressurized with air and/or other gas(es). Rapid depressurization of the chamber may produce the aforementioned pressure differential, leading to powder movement away from the parts.

IPC Classes  ?

  • B22F 10/68 - Cleaning or washing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B22F 12/70 - Gas flow means
  • B08B 5/00 - Cleaning by methods involving the use of air flow or gas flow

15.

Low-Cost High-Purity Vacuum Pumps and Systems

      
Application Number 17802722
Status Pending
Filing Date 2021-03-01
First Publication Date 2023-04-13
Owner Desktop Metal, Inc. (USA)
Inventor Woodard, Nathan

Abstract

Disclosed is a pumping system with reduced contamination. A vacuum pump system includes a mechanical vacuum pump mechanism within a hermetic pump that hermetically isolates the pump mechanism from ambient air. A pump inlet is hermetically sealed to the hermetic pump housing. A pump outlet is hermetically sealed at one end to the hermetic pump housing and at the other end to an inlet of a Peclet seal tube. The vacuum pump system produces a vacuum in a vacuum processing chamber. A sweep gas source injects a sweep gas into at least one of (i) the hermetic pump housing and (ii) the inlet of the Peclet seal tube. The sweep gas and a process gas flow through the Peclet seal tube to substantially isolate against the backflow of the ambient air through the Peclet seal tube.

IPC Classes  ?

  • F27B 5/04 - Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated adapted for treating the charge in vacuum or special atmosphere
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • F27B 5/16 - Arrangements of air or gas supply devices

16.

Systems and methods for adjusting a three-dimensional (3D) model during additive manufacturing

      
Application Number 16453691
Grant Number 11597153
Status In Force
Filing Date 2019-06-26
First Publication Date 2023-03-07
Grant Date 2023-03-07
Owner Desktop Metal, Inc. (USA)
Inventor
  • Barbati, Alexander C.
  • Gibson, Michael Andrew
  • Hudelson, George
  • Mykulowycz, Nicholas Mark
  • Kernan, Brian D.
  • Tuncer, Nihan

Abstract

Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

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]
  • 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 64/379 - Handling of additively manufactured objects, e.g. using robots
  • 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 40/20 - Post-treatment, e.g. curing, coating or polishing

17.

RETORT FOR IMPROVED THERMAL PROCESSING OF SINTERABLE OBJECTS

      
Application Number 17880050
Status Pending
Filing Date 2022-08-03
First Publication Date 2023-02-09
Owner Desktop Metal, Inc. (USA)
Inventor Barbati, Alexander

Abstract

A retort for thermally processing sinterable objects including a retort body having an interior cavity configured to receive at least one part for sintering. The retort body includes a retort inlet, a fore volume, an inlet plenum, an outlet plenum and a retort outlet. The retort inlet is configured to be fluidly connected to a process gas inlet tube and receive a flow of process gas. The retort inlet is fluidly connected to the fore volume, the fore volume being configured to receive a cleansing object. The fore volume is fluidly connected to the inlet plenum, which is fluidly connected to the interior cavity, which is in turn fluidly connected to the outlet plenum. The outlet plenum is fluidly connected to the retort outlet which is configured to be fluidly connected to an effluent gas outlet tube via a Peclet sealing element.

IPC Classes  ?

  • F27B 5/16 - Arrangements of air or gas supply devices
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor

18.

METHOD OF COMPENSATING FOR SINTERING WARPAGE DUE TO POWDER SPREADING DENSITY VARIATIONS IN BINDER JET 3D PRINTING

      
Application Number 17898322
Status Pending
Filing Date 2022-08-29
First Publication Date 2022-12-29
Owner Desktop Metal, Inc. (USA)
Inventor Roberts, Andrew Fiske

Abstract

A method of compensating for sintering warpage due to powder spreading density variations in binder jetting additive manufacturing, including receiving an initial design file defining an object geometry, representing the object geometry as a part mesh and filling the mesh with a grid of voxels to create a voxel grid, each voxel having at least one shrinkage coefficient. For each voxel, determining a distortion factor caused by a powder density variation induced during a powder spreading process and adjusting the at shrinkage coefficient of each voxel according to its respective distortion factor. Next, a shrinkage of the grid of voxels is simulated according to a sintering process. A negative compensation is applied to the voxel grid, according to the simulated shrinkage of the grid of voxels, to form a compensated voxel grid. Lastly, the change in the voxel grid is mapped to the compensated voxel grid onto the part mesh to create a pre-processed compensated part mesh.

IPC Classes  ?

  • B22F 10/85 - Data acquisition or data processing for controlling or regulating additive manufacturing processes
  • 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
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • G06T 17/20 - Wire-frame description, e.g. polygonalisation or tessellation
  • G06T 19/20 - Editing of 3D images, e.g. changing shapes or colours, aligning objects or positioning parts
  • G06F 30/20 - Design optimisation, verification or simulation

19.

METHOD OF COMPENSATING FOR SHRINKAGE AND DISTORTION USING SCANS

      
Application Number 17898309
Status Pending
Filing Date 2022-08-29
First Publication Date 2022-12-29
Owner Desktop Metal, Inc. (USA)
Inventor Roberts, Andrew Fiske

Abstract

A method of compensating for shrinking and distortion of an object resulting from a manufacturing process. A scan is performed of an object following a manufacturing process to produce scan data. The scan data is aligned to a part mesh of the object. The part mesh is adjusted to substantially coincide with the scan data by moving part mesh vertices. Delta vectors are computed by subtracting initial part mesh vertex positions from final part mesh vertex positions. The inverse of the delta vectors are applied to the preprocessed part mesh to give a scan adjusted pre-processed shape.

IPC Classes  ?

  • G06T 7/33 - Determination of transform parameters for the alignment of images, i.e. image registration using feature-based methods
  • G06T 17/20 - Wire-frame description, e.g. polygonalisation or tessellation
  • G06T 7/37 - Determination of transform parameters for the alignment of images, i.e. image registration using transform domain methods

20.

Layer Spreading and Compaction in Binder Jet 3D Printing

      
Application Number 17525718
Status Pending
Filing Date 2021-11-12
First Publication Date 2022-11-10
Owner Desktop Metal, Inc. (USA)
Inventor
  • Hudelson, George
  • Barbati, Alexander C

Abstract

A method of conditioning layers of build material powder for metal additive manufacturing including depositing an amount of build material powder on a work surface, the amount of build material powder having a lower surface separated from an upper surface by a height. A roller is traversed across the work surface in a first direction while rotating the roller in a direction opposed to the first direction. During the step of traversing the roller, a lower surface of the roller extends below the upper surface of the amount of build material powder by a distance. The roller has a surface conditioning configured to, in conjunction with a controlled speed of the rotation of the roller, provide a powder density in a compacted layer within a predetermined powder density range.

IPC Classes  ?

  • B22F 10/37 - Process control of powder bed aspects, e.g. density
  • B22F 12/63 - 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

21.

THE JETTING PERFORMANCE OF MOLTEN METAL ALLOYS BY CONTROLLING THE CONCENTRATION OF KEY ALLOYING ELEMENTS

      
Application Number 17670395
Status Pending
Filing Date 2022-02-11
First Publication Date 2022-08-18
Owner Desktop Metal, Inc. (USA)
Inventor
  • Bauer, Uwe
  • Gibson, Mark
  • Sachs, Emanuel
  • Barbati, Robert
  • Barbati, Alexander
  • Kernan, Brian

Abstract

A method for improving part quality in additive manufacturing involving jetting liquid metal. Limiting the amounts of magnesium and zinc in a meniscus material to below predetermined thresholds improves jetting quality. Further, ensuring an amount of Strontium is above a predetermined threshold further improves jetting of the liquid metal.

IPC Classes  ?

  • B22F 10/22 - Direct deposition of molten metal
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B22D 23/00 - Casting processes not provided for in groups
  • C22C 21/06 - Alloys based on aluminium with magnesium as the next major constituent
  • 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
  • B22F 12/53 - Nozzles

22.

CONTROLLING MENISCUS POSITION FOR MAGNETOHYDRODYNAMIC METAL MANUFACTURING

      
Application Number 17727331
Status Pending
Filing Date 2022-04-22
First Publication Date 2022-08-11
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Emanuel Michael
  • Hoisington, Paul A.

Abstract

Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. Electric current delivered to a meniscus of the liquid metal in a quiescent state can be directed to exert a pullback force on the liquid metal. The pullback force can be sufficient to draw the liquid metal, in the quiescent state, in a direction toward the nozzle to reduce the likelihood of unintended wetting of surfaces of the nozzle between uses of the nozzle.

IPC Classes  ?

  • B22F 3/115 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor by spraying molten metal, i.e. spray sintering, spray casting
  • 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
  • B05B 5/025 - Discharge apparatus, e.g. electrostatic spray guns
  • B22F 10/10 - Formation of a green body
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder

23.

TECHNIQUES FOR CONTROLLING BUILD MATERIAL FLOW CHARACTERISTICS IN ADDITIVE MANUFACTURING AND RELATED SYSTEMS AND METHODS

      
Application Number 17292816
Status Pending
Filing Date 2019-11-08
First Publication Date 2022-08-11
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Michael A.
  • Barbati, Alexander C.
  • Hudelson, George
  • Nick, Robert J.
  • Hoisington, Paul A.
  • Kernan, Brian D.

Abstract

Embodiments described herein relate to methods and systems for controlling the packing behavior of powders for additive manufacturing applications. In some embodiments, a method for additive manufacturing includes adding a packing modifier to a base powder to form a build material. The build material may be spread to form a layer across a powder bed, and the build material may be selectively joined along a two-dimensional pattern associated with the layer. The steps of spreading a layer of build material and selectively joining the build material in the layer may be repeated to form a three-dimensional object. The packing modifier may be selected to enhance one or more powder packing and/or powder flow characteristics of the base powder to provide for improved uniformity of the additive manufacturing process, promote sintering, and/or to enhance the properties of the manufactured three-dimensional objects.

IPC Classes  ?

  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B22F 10/60 - Treatment of workpieces or articles after build-up
  • B22F 3/26 - Impregnating
  • B22F 1/16 - Metallic particles coated with a non-metal

24.

INTERFACE MATERIAL FORMULATIONS FOR ADDITIVE FABRICATION

      
Application Number 17583825
Status Pending
Filing Date 2022-01-25
First Publication Date 2022-08-11
Owner Desktop Metal, Inc. (USA)
Inventor Barbati, Alexander C.

Abstract

Improved formulations of an interface material are described. These formulations may, in at least some cases, match and/or accommodate dimensional changes in the part and/or support structure throughout thermal processing (e.g., debind and sintering, or sintering only). Furthermore, these formulations may also maintain the property of resisting bonding between the interface and the part and/or support structure while also maintaining a physical separation between the part and support structure. In some cases, an improved interface material may accommodate strain associated with the shrinkage of a part (and optionally support structure) during sintering while also minimally impacting the ability of the part (and optionally support structure) to shrink or otherwise change in dimension. In some cases, the interface material may include one or more fugitive phases that are removed during thermal processing (e.g., through pyrolysis of the fugitive phase(s)).

IPC Classes  ?

25.

Three-dimensional printer

      
Application Number 29784107
Grant Number D0955449
Status In Force
Filing Date 2021-05-18
First Publication Date 2022-06-21
Grant Date 2022-06-21
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin
  • Kramer, Matthew

26.

Z-AXIS MEASUREMENT AND CONTROL IN 3D PRINTING OF METAL

      
Application Number 17437402
Status Pending
Filing Date 2020-03-20
First Publication Date 2022-06-02
Owner Desktop Metal, Inc. (USA)
Inventor Gibson, Mark Gardner

Abstract

Disclosed is the measurement and control of height in the Z-axis of layers produced in an additive manufacturing process. The height of layers being deposited can be monitored, which may involve the use of a fiducial tower to measure a global errors or optical or other means to measure layers on a layer-by-layer basis. Droplet size, pitch and other conditions may be modified to ameliorate or correct detected errors.

IPC Classes  ?

  • B22F 10/31 - Calibration of process steps or apparatus settings, e.g. before or during manufacturing
  • B22F 10/22 - Direct deposition of molten metal
  • B22F 12/90 - Means for process control, e.g. cameras or sensors
  • B22F 10/80 - Data acquisition or data processing
  • 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
  • B22F 12/53 - Nozzles

27.

DROSS REMOVAL METHODS AND DEVICES FOR MAGNETOHYDRODYNAMIC JETTING OF METALS IN 3D PRINTING APPLICATIONS

      
Application Number 17438438
Status Pending
Filing Date 2020-03-20
First Publication Date 2022-05-26
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Mark Gardner
  • Bell, Julian
  • Sachs, Emanuel Michael

Abstract

A dross removal system for magnetohydrodynamic additive. A vacuum source is used to create a pressure differential at a nozzle opening sufficient to collect dross from a pool of molten metal. The dross and any collected molten metal can be captured in a waste bin for later disposal. 308

IPC Classes  ?

  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B08B 5/04 - Cleaning by suction, with or without auxiliary action
  • B08B 13/00 - Accessories or details of general applicability for machines or apparatus for cleaning

28.

Controlled environment for additive manufacturing

      
Application Number 17438439
Grant Number 11980940
Status In Force
Filing Date 2020-03-20
First Publication Date 2022-05-19
Grant Date 2024-05-14
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Emanuel Michael
  • Bell, Julian
  • Bandiera, Nicholas Graham

Abstract

A controlled environment system for the additive manufacture of metal objects using magnetohydrodynamic jetting. A sealing plate is placed against an Péclet gap seal of a volume enclosure. A flow of inert gas is used to maintain a high-purity volume in the interior of the volume enclosure. A print head accesses the interior and delivers build material through a hole in the sealing plate. A build plate is movable relative to the sealing plate within the interior of the volume enclosure on which objects can be fabricated.

IPC Classes  ?

  • B33Y 10/00 - Processes of additive manufacturing
  • B22D 23/00 - Casting processes not provided for in groups
  • B22F 10/22 - Direct deposition of molten metal
  • B22F 12/70 - Gas flow 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 40/00 - Auxiliary operations or equipment, e.g. for material handling

29.

Three-dimensional printer

      
Application Number 29691984
Grant Number D0952008
Status In Force
Filing Date 2019-05-21
First Publication Date 2022-05-17
Grant Date 2022-05-17
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin
  • Fishman, Alex
  • Fulop, Ric
  • Chin, Rick
  • Myerberg, Jonah Samuel
  • Behar, Yves
  • Heiman, Brandon

30.

SYSTEMS, DEVICES, AND METHODS FOR PURIFYING ATMOSPHERE IN A VACUUM FURNACE

      
Application Number 17460028
Status Pending
Filing Date 2021-08-27
First Publication Date 2022-03-03
Owner Desktop Metal, Inc. (USA)
Inventor
  • Woodard, Nathan
  • Holenarasipura Raghu, Shashank
  • Gibson, Michael Andrew

Abstract

The present disclosure includes a furnace for heating and/or sintering one or more three-dimensional printed metal parts. The furnace includes a furnace chamber, insulation within the furnace chamber, a retort within the furnace chamber, and one or more getters containing getter material. The retort is configured to receive the one or more three-dimensional printed metal parts.

IPC Classes  ?

  • F27B 5/04 - Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated adapted for treating the charge in vacuum or special atmosphere
  • F27B 5/16 - Arrangements of air or gas supply devices
  • F27D 17/00 - Arrangement for using waste heat; Arrangement for using, or disposing of, waste gases
  • F27D 7/06 - Forming or maintaining special atmospheres or vacuum within heating chambers

31.

Depowdering station

      
Application Number 29709061
Grant Number D0944472
Status In Force
Filing Date 2019-10-10
First Publication Date 2022-02-22
Grant Date 2022-02-22
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin

32.

TWO-STAGE SINTERING FURNACE AND METHODS OF OPERATING THEREOF

      
Application Number 17436790
Status Pending
Filing Date 2020-03-13
First Publication Date 2022-01-20
Owner Desktop Metal, Inc. (USA)
Inventor
  • Woodard, Nathan
  • Fontana, Richard Remo
  • Weiss, Robert Edward

Abstract

A sintering and debinding system includes a debinding chamber configured to switch between an open state and a closed state, the open state being configured to permit receipt or removal of at least one part within or from the debinding chamber and a sintering chamber operably connected to the debinding chamber and being vertically positioned above or below the debinding chamber. The sintering system also includes a shelf structure configured to receive the at least one part, the shelf structure being movable between the debinding chamber and the sintering chamber and a gate valve configured to switch between an open state and a closed state, the gate valve being configured to selectively permit or block fluid communication between the debinding chamber and the sintering chamber. The gate valve is configured such that: when the gate valve is in an open state, fluid communication between the debinding chamber and the sintering chamber is permitted and the shelf structure is movable between the debinding chamber and the sintering chamber. The gate valve is further configured such that, when the gate valve is in the closed state, fluid communication between the debinding chamber and sintering chamber is restricted, and at least one of: (i) movement of the shelf structure between the debinding chamber and the sintering chamber is restricted or (ii) the debinding chamber is configured to permit receipt within and removal of the at least one part from the debinding chamber.

IPC Classes  ?

  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B22F 3/10 - Sintering only
  • F27B 9/14 - Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the means by which the charge is moved during treatment
  • F27B 17/00 - Furnaces of a kind not covered by any of groups

33.

SEALED FURNACE

      
Application Number 17429763
Status Pending
Filing Date 2020-02-11
First Publication Date 2022-01-13
Owner Desktop Metal, Inc. (USA)
Inventor
  • Woodard, Nathan
  • Myerberg, Jonah Samuel
  • Sachs, Emanuel M
  • Fontana, Richard Remo
  • Weiss, Robert Edward
  • Chiang, Yet-Ming
  • Dipietro, Stephen
  • Bandiera, Nicholas Graham

Abstract

A furnace may include an outer wall defining a chamber, the chamber including an internal cavity configured to receive one or more parts, at least one heater positioned within the chamber, the at least one heater being configured to generate temperatures of at least about 800 degrees Celsius within the internal cavity, and a vacuum pump configured to apply a vacuum to at least a portion of the chamber. The furnace may also include at least one layer of inner insulation and at least one layer of outer insulation disposed outward of the inner insulation with respect to the chamber, the at least one layer of outer insulation being sealed with respect to the at least one layer of inner insulation.

IPC Classes  ?

  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B22F 3/10 - Sintering only
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • F27B 5/04 - Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated adapted for treating the charge in vacuum or special atmosphere
  • F27B 5/08 - Arrangements of linings
  • F27D 1/00 - Casings; Linings; Walls; Roofs
  • F27D 99/00 - Subject matter not provided for in other groups of this subclass
  • F27B 5/18 - Arrangement of controlling, monitoring, alarm or like devices

34.

Mold lock remediation

      
Application Number 17474216
Grant Number 11718038
Status In Force
Filing Date 2021-09-14
First Publication Date 2021-12-30
Grant Date 2023-08-08
Owner Desktop Metal, Inc. (USA)
Inventor
  • Chin, Ricardo
  • Reeves, Blake Z.

Abstract

Mold lock is remediated by performing a layer-by-layer, two-dimensional analysis to identify unconstrained removal paths for any support structure or material within each two-dimensional layer, and then ensuring that aligned draw paths are present for all adjacent layers, all as more specifically described herein. Where locking conditions are identified, a sequence of modification rules are then applied, such as by breaking support structures into multiple, independently removable pieces. By addressing mold lock as a series of interrelated two-dimensional geometric problems, and reserving three-dimensional remediation strategies for more challenging, complex mold lock conditions, substantial advantages can accrue in terms of computational speed and efficiency.

IPC Classes  ?

  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B28B 17/00 - SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER - Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
  • B28B 1/00 - Producing shaped articles from the material
  • H04N 1/409 - Edge or detail enhancement; Noise or error suppression
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B22F 10/20 - Direct sintering or melting
  • B22F 10/40 - Structures for supporting workpieces or articles during manufacture and removed afterwards
  • B22F 10/64 - Treatment of workpieces or articles after build-up by thermal means
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/10 - Processes of additive manufacturing

35.

COMPOSITIONS COMPRISING A BINDER AND A POWDER, AND ASSOCIATED METHODS

      
Application Number 17285650
Status Pending
Filing Date 2019-10-16
First Publication Date 2021-12-23
Owner DESKTOP METAL, INC. (USA)
Inventor
  • Rushkin, Ilya L.
  • Bai, Yun
  • Lee, Shannon

Abstract

The present invention generally relates to compositions comprising a binder and a metal powder, and associated methods. Some compositions provided include a polymer and a metal powder. Some compositions provided include a binder formulation and a metal powder. The binder formulation generally includes a first liquid and a polymer. The binder formulation may be a solution. The polymer may include a nitrogen-containing repeat unit. The metal powder may include a noble metal. Some methods provided include combining a metal powder with a binder formulation. Methods provided include but are not limited to additive manufacturing processes and injection molding processes.

IPC Classes  ?

  • B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • 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
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

36.

ROD FEEDER FOR THREE-DIMENSIONAL (3D) PRINTING

      
Application Number 17458697
Status Pending
Filing Date 2021-08-27
First Publication Date 2021-12-16
Owner Desktop Metal, Inc. (USA)
Inventor Titchener, Paul

Abstract

An apparatus, and corresponding method, feeds build material, in the form of rods, to a drive system in a three-dimensional (3D) printing system. The apparatus dispenses a rod to a media tray and into a first groove defined by a flipper arm. The flipper arm is in a substantially horizontal position supported by a bottom ridge of the media tray. The flipper arm is rotated away from the bottom ridge and toward a stopper coupled to the flipper arm and the media tray. The stopper defines a second groove. The apparatus deposits the rod into the drive system via a feed shaft formed by the first and second grooves of the flipper arm and stopper, respectively. The apparatus enables high-speed 3D printing using the rods by overcoming challenges in loading the rods due to brittleness of the rods.

IPC Classes  ?

  • B29C 64/321 - Feeding
  • 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
  • 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 64/255 - Enclosures for the building material, e.g. powder containers
  • B22F 10/10 - Formation of a green body

37.

Techniques to Improve MHD Jetting Performance

      
Application Number 17278050
Status Pending
Filing Date 2019-09-09
First Publication Date 2021-12-09
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Mark Gardner
  • Sachs, Emanuel Michael
  • Bell, Julian

Abstract

An improved additive manufacturing system for manufacturing metal parts by magnetohydrodynamic printing liquid metal. A monitoring system including at least one camera capturing light reflected from a strobe light source. Images of the droplets are captured during their jetting and analyzed to determine whether the jetting performance is meeting specifications. A nozzle of the system has a nozzle bottom and a nozzle stem extending outward therefrom on which a meniscus of liquid metal can form. The nozzle is cleaned by bringing a ceramic rod in the vicinity of the nozzle and jetting a bead of metal which is rotated against the nozzle to remove an amount of dross.

IPC Classes  ?

  • B22F 10/80 - Data acquisition or data processing
  • 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
  • B22D 23/00 - Casting processes not provided for in groups
  • B22F 10/22 - Direct deposition of molten metal
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B22F 12/90 - Means for process control, e.g. cameras or sensors
  • B22F 12/53 - Nozzles

38.

Methods and systems for generatively designing assemblies of mechanical parts

      
Application Number 16887834
Grant Number 11714931
Status In Force
Filing Date 2020-05-29
First Publication Date 2021-12-02
Grant Date 2023-08-01
Owner Desktop Metal, Inc. (USA)
Inventor
  • Roberts, Andrew Fiske
  • Chin, Ricardo

Abstract

Methods and systems are disclosed for generatively designing a model of an assembly of mechanical parts. One method includes receiving a first set of constraints for a first part; determining a spatial relationship between the first part and a second part; updating the first set of constraints for the first part based on at least the spatial relationship between the first part and the second part; updating a second set of constraints for the second part based on at least the updated first set up constraints and/or the spatial relationship between the first part and the second part; and generating a model for the first part based on the updated first set of constraints.

IPC Classes  ?

  • G06F 30/17 - Mechanical parametric or variational design
  • H04L 67/10 - Protocols in which an application is distributed across nodes in the network

39.

SYSTEMS AND METHODS FOR CALIBRATION FEEDBACK FOR ADDITIVE MANUFACTURING

      
Application Number 17400313
Status Pending
Filing Date 2021-08-12
First Publication Date 2021-12-02
Owner Desktop Metal, Inc. (USA)
Inventor
  • Preston, Aaron
  • Mykulowycz, Nicholas

Abstract

A camera assembly is employed in additive manufacturing to improve the fidelity of a printed object. The camera may scan the surface of a build plate of a 3D printer and an object as it is being printed to generate image data. The image data is processed to detect errors in the build plate or printed object. The printer compensates for the detected errors, which can including modifying the printer configuration and/or modifying the instructions for printing a given object. Using the updated configuration, subsequent objects may then be printed, under a corrected process, to produce an object with fidelity to an original object model.

IPC Classes  ?

  • B22F 10/10 - Formation of a green body
  • 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
  • B22F 3/22 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor for producing castings from a slip
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • 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 64/386 - Data acquisition or data processing for additive manufacturing

40.

PROFILED RAILS FOR IN MULTI-DIRECTIONAL BINDER JETTING

      
Application Number 16327915
Status Pending
Filing Date 2018-04-20
First Publication Date 2021-11-11
Owner Desktop Metal, Inc. (USA)
Inventor
  • Myerberg, Jonah
  • Fulop, Ricardo
  • Fontana, Richard
  • Martin, Charles Edward
  • Schuster, Brett
  • Sachs, Emanuel Michael

Abstract

The devices, systems, and methods of the present disclosure are directed to spreader positioning techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, an additive manufacturing system may include a roller and a print carriage. In a layer-by-layer fabrication process, the roller may move in advance of the print carriage over a dimension of a volume to spread a respective layer of powder onto which the print carriage delivers a binder. Controlling the position of the roller may facilitate achieving consistent layer characteristics which, in turn, may facilitate fabrication of high quality parts.

IPC Classes  ?

  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • 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
  • B28B 1/00 - Producing shaped articles from the material
  • B22F 12/63 - Rollers
  • B22F 12/70 - Gas flow means
  • B22F 10/68 - Cleaning or washing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B22F 10/80 - Data acquisition or data processing
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

41.

PULSE SHAPING TECHNIQUES TO IMPROVE MAGNETOHYDRODYNAMIC PRINTING PERFORMANCE

      
Application Number 17278055
Status Pending
Filing Date 2019-09-20
First Publication Date 2021-11-11
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Mark Gardner
  • Sachs, Emanuel Michael

Abstract

A method of additive manufacturing using magnetohydrodynamic (MHD) printing of liquid metal. A first current pulse is applied to a liquid metal in a nozzle to eject a droplet from a discharge orifice. A second current pulse is applied to the liquid metal in the nozzle to reduce an amplitude of the oscillations in a meniscus on the discharge orifice. The second current pulse can be either of an opposite or the same polarity as the first current pulse and is timed according to according to the oscillation.

IPC Classes  ?

  • B22F 10/22 - Direct deposition of molten metal
  • 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
  • B22F 10/85 - Data acquisition or data processing for controlling or regulating additive manufacturing processes
  • B22F 12/53 - Nozzles
  • B22D 23/00 - Casting processes not provided for in groups

42.

Binder jetting in additive manufacturing of inhomogeneous three-dimensional parts

      
Application Number 16328012
Grant Number 11702367
Status In Force
Filing Date 2018-10-17
First Publication Date 2021-10-28
Grant Date 2023-07-18
Owner Desktop Metal, Inc. (USA)
Inventor
  • Barbati, Alexander
  • Gibson, Michael Andrew
  • Tuncer, Nihan
  • Kernan, Brian

Abstract

Devices, systems, and methods are directed to binder jetting for forming three-dimensional parts having controlled, macroscopically inhomogeneous material composition. In general, a binder may be delivered to each layer of a plurality of layers of a powder of inorganic particles. An active component may be introduced, in a spatially controlled distribution, to at least one of the plurality of layers such that the binder, the powder of inorganic particles, and the active component, in combination, form an object. The object may be thermally processed into a three-dimensional part having a gradient of one or more physicochemical properties of a material at least partially formed from thermally processing the inorganic particles and the active component of the object.

IPC Classes  ?

  • C04B 35/111 - Fine ceramics
  • B33Y 10/00 - Processes of additive manufacturing
  • 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
  • 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
  • C04B 35/634 - Polymers
  • C04B 35/565 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • 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
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 12/55 - Two or more means for feeding material
  • B28B 1/00 - Producing shaped articles from the material
  • C09D 11/023 - Emulsion inks
  • C09D 11/033 - Printing inks characterised by features other than the chemical nature of the binder characterised by the solvent
  • C09D 11/037 - Printing inks characterised by features other than the chemical nature of the binder characterised by the pigment
  • C09D 11/10 - Printing inks based on artificial resins
  • C09D 11/322 - Pigment inks
  • C09D 11/38 - Inkjet printing inks characterised by non-macromolecular additives other than solvents, pigments or dyes
  • C09D 11/54 - Inks based on two liquids, one liquid being the ink, the other liquid being a reaction solution, a fixer or a treatment solution for the ink
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 12/33 - Platforms or substrates translatory in the deposition plane
  • B22F 10/30 - Process control

43.

SYSTEMS, METHODS, AND DEVICES FOR ACTUATION OF BUILD MATERIAL

      
Application Number 17238006
Status Pending
Filing Date 2021-04-22
First Publication Date 2021-10-28
Owner Desktop Metal, Inc. (USA)
Inventor
  • Preston, Aaron M.
  • Haider, Charles J.
  • Titchener, Paul
  • Barbati, Alexander C.
  • Mykulowycz, Nicholas

Abstract

An actuation method comprising applying a force to a first rod of build material disposed within an actuation volume. The first rod of build material may include at least one metal. The method may further comprise moving the first rod of build material in a direction substantially parallel to or substantially coaxial with a longitudinal axis of the first rod of build material toward an extrusion head and loading a second rod of build material into the actuation volume. The second rod of build material may include at least one metal. A longitudinal axis of the second rod may be substantially coaxial with the longitudinal axis of the first rod. The applying step and the moving step may be repeated for the second rod of build material.

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
  • B29C 64/321 - Feeding
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/241 - Driving means for rotary motion
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B33Y 10/00 - Processes of additive manufacturing

44.

Frequency Mapping for Magnetohydrodynamic Jetting of Metals in 3D Printing Applications

      
Application Number 17232368
Status Pending
Filing Date 2021-04-16
First Publication Date 2021-10-21
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Mark Gardner
  • Sachs, Emanuel Michael

Abstract

A method of developing a frequency map for an MHD jetting nozzle includes filling the MHD jetting nozzle with a liquid metal. The MHD jetting nozzle is excited with a series of jetting pulses delivered at a range of frequencies the vibration response of the MHD jetting nozzle and/or a meniscus of jetting material is measured.

IPC Classes  ?

  • B22D 23/00 - Casting processes not provided for in groups
  • 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

45.

Nozzle Temperature Control Techniques for Magnetohydrodynamic Jetting of Metals in 3D Applications

      
Application Number 17232343
Status Pending
Filing Date 2021-04-16
First Publication Date 2021-10-21
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Mark Gardner
  • Bell, Julian
  • Sachs, Emanuel Michael
  • Bandiera, Nicholas

Abstract

A nozzle assembly for metal additive manufacturing using magnetohydrodynamic jetting. A nozzle defines a reservoir and a discharge region having a discharge orifice. A thick film heating system disposed on an exterior of the nozzle and including a first contact pad and a second contact pad connected by a heating pathway heats build material in the nozzle to a liquid state. A first electrode and a second electrode together configured to deliver an electrical current through the liquid build material in the discharge region while a magnet system delivers a magnetic field perpendicular the electrical current, thereby jetting liquid metal to form successive build layers.

IPC Classes  ?

  • B22D 23/00 - Casting processes not provided for in groups
  • 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

46.

MATERIAL SYSTEMS FOR ADDITIVE MANUFACTURING

      
Application Number 16328632
Status Pending
Filing Date 2017-12-14
First Publication Date 2021-09-16
Owner Desktop Metal, Inc. (USA)
Inventor
  • Fulop, Ricardo
  • Bose, Animesh
  • Gibson, Michael Andrew
  • Fontana, Richard Remo
  • Myerberg, Jonah Samuel

Abstract

Techniques and compositions are disclosed for three-dimensional printing with powder/binder systems including, but not limited to, metal injection molding powder materials, highly-filled polymer composites, and any other materials suitable for handling with various additive manufacturing techniques, and further suitable for subsequent debinding and thermal processing into a final object.

IPC Classes  ?

  • B22F 10/18 - Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B22F 3/24 - After-treatment of workpieces or articles
  • B28B 1/00 - Producing shaped articles from the material

47.

Multi-directional binder jetting additive manufacturing

      
Application Number 16328272
Grant Number 11623389
Status In Force
Filing Date 2018-04-20
First Publication Date 2021-09-16
Grant Date 2023-04-11
Owner Desktop Metal, Inc. (USA)
Inventor
  • Myerberg, Jonah
  • Fulop, Ricardo
  • Schuster, Brett
  • Sachs, Emanuel Michael
  • Hoisington, Paul A.
  • Hart, Anastasios John
  • Vaillancourt, Keith
  • Garrant, Steven
  • Hudelson, George

Abstract

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

IPC Classes  ?

  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 3/16 - Both compacting and sintering in successive or repeated steps
  • B22F 3/18 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor by using pressure rollers
  • 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
  • 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
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 10/85 - Data acquisition or data processing for controlling or regulating additive manufacturing processes
  • B22F 12/63 - Rollers
  • B22F 12/52 - Hoppers
  • B22F 1/14 - Treatment of metallic powder
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
  • B22F 12/47 - Radiation means with translatory movement parallel to the deposition plane
  • B22F 12/55 - Two or more means for feeding material
  • B22F 10/10 - Formation of a green body
  • B22F 12/45 - Two or more
  • B22F 12/57 - Metering means
  • B22F 10/34 - Process control of powder characteristics, e.g. density, oxidation or flowability

48.

NANOPARTICLES IN BINDER JETTING FABRICATION OF METAL OBJECTS

      
Application Number 16328350
Status Pending
Filing Date 2018-02-21
First Publication Date 2021-09-09
Owner Desktop Metal, Inc. (USA)
Inventor
  • Barbati, Alexander C.
  • Fontana, Richard Remo
  • Gibson, Michael Andrew
  • Hudelson, George

Abstract

Devices, systems, and methods are directed to the use of nanoparticles for improving strength fabrication of three-dimensional objects formed through layer-by-layer process in which an ink is delivery of a binder delivered onto successive layers of a powder of inorganic particles in a powder bed. More specifically, nanoparticles of inorganic material can may be introduced into one or more layers of the metal powder in the powder bed and thermally processed to facilitate sinter necking, in the powder bed, of the metal particles forming the three-dimensional object. Such sinter necking in the powder bed can may improve strength of the three-dimensional objects being fabricated and, also or instead, can may reduce the likelihood of defects associated with subsequent processing of the three-dimensional objects (e.g., slumping and shrinking in a final sintering stage and/or inadequate densification of the final part).

IPC Classes  ?

  • B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • 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 80/00 - Products made by additive manufacturing
  • B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
  • B22F 10/10 - Formation of a green body
  • B22F 3/10 - Sintering only
  • B22F 7/02 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite layers
  • C08G 81/02 - Macromolecular compounds obtained by interreacting polymers in the absence of monomers, e.g. block polymers at least one of the polymers being obtained by reactions involving only carbon-to-carbon unsaturated bonds
  • C09D 11/102 - Printing inks based on artificial resins containing macromolecular compounds obtained by reactions other than those only involving unsaturated carbon-to-carbon bonds
  • C09D 11/106 - Printing inks based on artificial resins containing macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds

49.

THERMAL DEBINDING TECHNIQUES FOR ADDITIVE MANUFACTURING AND RELATED SYSTEMS AND METHODS

      
Application Number 17158673
Status Pending
Filing Date 2021-01-26
First Publication Date 2021-08-26
Owner DESKTOP METAL, INC. (USA)
Inventor
  • Reidy, John
  • Tuncer, Nihan
  • Bose, Animesh
  • Craven, Christopher
  • Barbati, Alexander C.
  • Fulop, Ricardo
  • Schofalvi, Karl-Heinz

Abstract

Techniques for debinding additively fabricated parts are described that do not require solvent debinding or catalytic debinding, and that may be performed using only thermal debinding in a furnace. As a result, in at least some cases debinding and sintering may take place sequentially within a single furnace. In some embodiments, the techniques may utilize particular materials as binders that allow for a thermal debinding process that does not negatively affect the parts.

IPC Classes  ?

  • B22F 3/10 - Sintering only
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 10/64 - Treatment of workpieces or articles after build-up by thermal means
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

50.

METHODS AND COMPOSITIONS FOR THE PREPARATION OF POWDERS FOR BINDER-BASED THREE-DIMENSIONAL ADDITIVE METAL MANUFACTURING

      
Application Number 17254805
Status Pending
Filing Date 2019-06-20
First Publication Date 2021-08-26
Owner DESKTOP METAL, INC. (USA)
Inventor Bose, Animesh

Abstract

Devices, systems, and methods are directed to coated powder for three dimensional additive manufacturing. The powder may include a first material coated with a second material, with the coating advantageously resisting segregation of the first material and the second material during handling processes associated with fabrication. The reduced segregation of the first material and the second material may facilitate forming finished three-dimensional parts with improved homogeneity of microstructures and, thus, improved physicochemical properties. More generally, the reduced segregation of the first material and the second material achievable through coating the first material with the second material may facilitate binder jet fabrication using a wider array of combinations of first material and second material as compared to binder jet fabrication using mixtures of constituent powders of the first material and the second material.

IPC Classes  ?

  • B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 10/62 - Treatment of workpieces or articles after build-up by chemical means
  • B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
  • 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 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing

51.

Techniques for depowdering additively fabricated parts via rapid pressure change and related systems and methods

      
Application Number 17274336
Grant Number 11511350
Status In Force
Filing Date 2019-09-13
First Publication Date 2021-08-12
Grant Date 2022-11-29
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Emanuel M.
  • Zero, Midnight

Abstract

Techniques for depowdering additively fabricated parts are described in which powder is separated from parts by creating a large pressure differential between the powder and parts and a nearby location. The pressure differential may cause gas to quickly flow into and/or around the powder and parts, thereby producing a force against the powder and parts. Since the powder is generally much lighter than the parts, this force may be much more effective at moving the powder than moving the parts. As a result, the powder and parts may be separated from one another. The pressure differential may be created in various ways, such as by holding the parts and part in a chamber that is pressurized with air and/or other gas(es). Rapid depressurization of the chamber may produce the aforementioned pressure differential, leading to powder movement away from the parts.

IPC Classes  ?

  • B22F 10/68 - Cleaning or washing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B22F 12/70 - Gas flow means
  • B08B 5/00 - Cleaning by methods involving the use of air flow or gas flow

52.

Particle stereolithography

      
Application Number 16328448
Grant Number 11826949
Status In Force
Filing Date 2017-11-14
First Publication Date 2021-08-05
Grant Date 2023-11-28
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Michael Andrew
  • Myerberg, Jonah Samuel
  • Fulop, Ricardo
  • Tarkanian, Michael J.
  • Chiang, Yet-Ming
  • Tobia, Jay
  • Lam, Olivia Molnar

Abstract

Systems, methods, components, and materials are disclosed for stereolithographic fabrication of three-dimensional, dense objects. A resin including at least one component of a binder system and dispersed particles can be exposed to an activation light source. The activation light source can cure the at least one component of the binder system to form a green object, which can include the at least one component of the binder system and the particles. A dense object can be formed from the green object by removing the at least one component of the binder system in an extraction process and thermally processing particles to coalesce into the dense object.

IPC Classes  ?

  • 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 64/245 - Platforms or substrates
  • 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
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • C04B 35/486 - Fine ceramics
  • C04B 35/626 - Preparing or treating the powders individually or as batches
  • C04B 35/632 - Organic additives
  • C04B 35/638 - Removal thereof
  • G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F 7/004 - Photosensitive materials
  • A61K 6/807 - Preparations for artificial teeth, for filling teeth or for capping teeth comprising ceramics comprising magnesium oxide
  • A61K 6/818 - Preparations for artificial teeth, for filling teeth or for capping teeth comprising ceramics comprising zirconium oxide
  • A61K 6/822 - Preparations for artificial teeth, for filling teeth or for capping teeth comprising ceramics comprising rare earth metal oxides
  • A61K 6/833 - Glass-ceramic composites
  • C04B 35/01 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides
  • C04B 35/634 - Polymers
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 10/12 - Formation of a green body by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
  • B22F 10/50 - Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
  • A61L 27/46 - Composite materials, i.e. layered or containing one material dispersed in a matrix of the same or different material having a macromolecular matrix with phosphorus-containing inorganic fillers
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • 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
  • B22F 7/04 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite layers with one or more layers not made from powder, e.g. made from solid metal
  • B28B 1/00 - Producing shaped articles from the material
  • B33Y 10/00 - Processes of additive manufacturing
  • B22F 3/26 - Impregnating
  • B22F 7/08 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
  • B33Y 80/00 - Products made by additive manufacturing
  • B82Y 30/00 - Nanotechnology for materials or surface science, e.g. nanocomposites
  • B82Y 40/00 - Manufacture or treatment of nanostructures
  • C22C 9/06 - Alloys based on copper with nickel or cobalt as the next major constituent
  • C22C 19/03 - Alloys based on nickel or cobalt based on nickel
  • B22F 12/90 - Means for process control, e.g. cameras or sensors
  • B22F 10/64 - Treatment of workpieces or articles after build-up by thermal means
  • B22F 1/102 - Metallic powder coated with organic material
  • G03F 7/027 - Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
  • B22F 3/10 - Sintering only
  • B29K 509/02 - Ceramics

53.

Techniques for depowdering additively fabricated parts and related systems and methods

      
Application Number 17117200
Grant Number 11865615
Status In Force
Filing Date 2020-12-10
First Publication Date 2021-08-05
Grant Date 2024-01-09
Owner Desktop Metal, Inc. (USA)
Inventor
  • Go, Jamison
  • Sachs, Emanuel M.
  • Goldblatt, Michael
  • Von Loesecke, Jeffrey

Abstract

Techniques for depowdering additively fabricated parts are described. The techniques utilize various mechanisms to separate powder from parts. For instance, techniques for depowdering described herein may include fabrication of auxiliary structures in addition to fabrication of parts. Certain auxiliary structures may aid with depowdering operations, and may be fabricated along with parts during an additive fabrication process. The auxiliary structures may be shaped and/or have positional and/or geometrical relationships to the parts during fabrication. For instance, an auxiliary structure may include a cage structure fabricated around one or more parts.

IPC Classes  ?

  • B22F 10/68 - Cleaning or washing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B08B 7/04 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass by a combination of operations
  • B03C 1/30 - Combinations with other devices, not otherwise provided for
  • B08B 5/02 - Cleaning by the force of jets, e.g. blowing-out cavities

54.

METHODS AND DEVICES FOR THREE-DIMENSIONAL PRINTING

      
Application Number 17151444
Status Pending
Filing Date 2021-01-18
First Publication Date 2021-08-05
Owner Desktop Metal, Inc. (USA)
Inventor
  • Barbati, Alexander C.
  • Hudelson, George Steven
  • Renner, Christopher Benjamin
  • Gibson, Michael Andrew

Abstract

A method for binder jetting a three-dimensional (3D) object includes receiving a geometry of the object to be printed and generating instructions for printing the object. Generating the instructions includes slicing the geometry of the object into a series of cross-sectional shapes corresponding to where a binder fluid will be deposited onto a powder bed to form the object, and including a plurality of negatively printed features within at least some of the series of cross-sectional shapes, wherein an amount of binder fluid to be deposited in the negatively printed features is less than an amount of binder fluid to be deposited in a remainder of the cross-sectional shape. The amount of binder fluid to be deposited in the negatively printed features and a size of the negatively printed features is configured to allow gas to escape from the powder bed.

IPC Classes  ?

  • B22F 10/80 - Data acquisition or data processing
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing

55.

Adaptive 3D printing

      
Application Number 17224676
Grant Number 11718037
Status In Force
Filing Date 2021-04-07
First Publication Date 2021-07-22
Grant Date 2023-08-08
Owner Desktop Metal, Inc. (USA)
Inventor
  • Chin, Ricardo
  • Gibson, Michael A.
  • Reeves, Blake Z.
  • Raghu, Shashank Holenarasipura

Abstract

Methods provide for fabricating objects through additive manufacturing in a manner that compensates for deformations introduced during post-print processing, such as sintering. An initial model may be divided into a plurality of segments, the initial model defining geometry of an object. For each of the segments, modified geometry may be calculated, where the modified geometry compensates for a predicted deformation. Print parameters can then be updated to incorporate the modified geometry, where the print parameters define geometry of the printed object (e.g., configuration settings of the printer, a tool path, an object model). The object may then be printed based on the updated print parameters.

IPC Classes  ?

  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • B22F 3/24 - After-treatment of workpieces or articles
  • G06F 30/17 - Mechanical parametric or variational design
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06T 17/20 - Wire-frame description, e.g. polygonalisation or tessellation
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 12/53 - Nozzles
  • B22F 10/32 - Process control of the atmosphere, e.g. composition or pressure in a building chamber
  • B22F 10/80 - Data acquisition or data processing

56.

Mixer

      
Application Number 29712250
Grant Number D0925620
Status In Force
Filing Date 2019-11-06
First Publication Date 2021-07-20
Grant Date 2021-07-20
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin

57.

Three-dimensional printer

      
Application Number 29709060
Grant Number D0922456
Status In Force
Filing Date 2019-10-10
First Publication Date 2021-06-15
Grant Date 2021-06-15
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin

58.

SYSTEM AND METHODS FOR PRINTING DEFECT DETECTION

      
Application Number 17116539
Status Pending
Filing Date 2020-12-09
First Publication Date 2021-06-10
Owner Desktop Metal, Inc. (USA)
Inventor
  • Hudelson, George
  • Mccambridge, Matthew
  • Dec, Jake
  • Legendre, Alexander

Abstract

An additive manufacturing method includes depositing a first amount of metal powder onto a powder bed of a printing system, spreading the first amount of metal powder across the powder bed to form a first layer, and depositing a first amount of binder material on the first layer. The additive manufacturing method also includes exposing the first layer to a first lighting condition, imaging the first layer under the first lighting condition to generate a first image, analyzing the first image of the first layer, and determining whether to adjust at least one printing parameter based on the analyzing.

IPC Classes  ?

  • B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
  • B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06T 7/00 - Image analysis
  • B33Y 10/00 - Processes of additive manufacturing

59.

ADDITIVE MANUFACTURING TECHNIQUES USING NOBLE METALS AND/OR COPPER METAL AND RELATED METHODS AND COMPOSITIONS

      
Application Number 17109306
Status Pending
Filing Date 2020-12-02
First Publication Date 2021-06-03
Owner DESKTOP METAL, INC. (USA)
Inventor
  • Rushkin, Ilya L.
  • Taylor, Shannon Lee
  • Bai, Yun
  • Reidy, John

Abstract

Methods of additive manufacturing using noble metals and/or copper metal, and binder compositions for use during the additive manufacturing methods, are generally described. In some instances, the methods of additive manufacturing include de-binding (and in some cases sintering steps) that afford metal-based composites, de-bound metal structures, and metal objects containing noble metals (e.g., silver, gold, platinum) and/or copper that have improved properties, such as relatively high densities. In certain aspects, combinations of certain metal powders (e.g., noble metal and/or copper powders) with certain binder compositions may result in improved properties of resulting metal objects produced by the additive manufacturing process, such as relatively low surface roughnesses. The binder compositions described may include a low molecular weight polymer (e.g., including an acrylic acid repeat unit) and, in some cases, a cross-linking agent.

IPC Classes  ?

  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 3/10 - Sintering only
  • 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

60.

Managing powder mobility in binder jetting for additive manufacturing

      
Application Number 17163721
Grant Number 11491716
Status In Force
Filing Date 2021-02-01
First Publication Date 2021-05-27
Grant Date 2022-11-08
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Emanuel Michael
  • Hudelson, George
  • Hoisington, Paul A.
  • Renner, Christopher Benjamin
  • Vaillancourt, Keith Roy
  • Moynihan, Edward Russell

Abstract

Devices, systems, and methods are directed to the use of vapor phase change in binder jetting processes for forming three-dimensional objects. In general, a vapor of a first fluid may be directed to a layer of a powder spread across a build volume. The vapor may condense to reduce mobility of the particles of the powder of the layer. For example, the condensing vapor may reduce the likelihood of particle ejection from the layer and, thus, may reduce the likelihood of clogging or otherwise degrading a printhead used to jet a second fluid (e.g., a binder) to the layer. Further, or instead, the condensing vapor may increase the density of the powder in the layer which, when repeated over a plurality of layers forming a three-dimensional object, may reduce the likelihood of slumping of the part during sintering.

IPC Classes  ?

  • 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/364 - Conditioning of environment
  • B29C 64/371 - Conditioning of environment using an environment other than air, e.g. inert gas
  • 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 64/209 - 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 64/30 - Auxiliary operations or equipment
  • 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
  • B28B 1/00 - Producing shaped articles from the material
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B22F 1/148 - Agglomerating
  • B22F 10/10 - Formation of a green body

61.

Systems and methods relating to 3D printing composite structures

      
Application Number 17258549
Grant Number 11883987
Status In Force
Filing Date 2019-07-10
First Publication Date 2021-05-27
Grant Date 2024-01-30
Owner DESKTOP METAL, INC. (USA)
Inventor Fetfatsidis, Konstantinos A.

Abstract

In part, the disclosure relates to systems and methods of layer-by-layer assembly of composite structures such as for parts or workpieces. Various additive and subtractive processes can be used. In various embodiments, prepreg tapes that include continuous reinforcing fibers are used. In one aspect, a system that includes printer heads is provided. The printer heads may, in some embodiments, be used for manufacturing high quality continuous fiber reinforced structural parts. In some embodiments, the system includes a first printer head configured to lay down tape (e.g., a thermoplastic tape that includes reinforcing fibers).

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 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
  • 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 64/209 - Heads; Nozzles
  • B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
  • B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
  • 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.

System and method for controlling powder bed density for 3D printing

      
Application Number 17166475
Grant Number 11998982
Status In Force
Filing Date 2021-02-03
First Publication Date 2021-05-27
Grant Date 2024-06-04
Owner Desktop Metal, Inc. (USA)
Inventor
  • Hudelson, George
  • Sachs, Emanuel M.
  • Jordan, Glenn A.
  • Zero, Midnight

Abstract

A system and corresponding method for additive manufacturing of a three-dimensional (3D) object to improve packing density of a powder bed used in the manufacturing process. The system and corresponding method enable higher density packing of the powder. Such higher density packing leads to better mechanical interlocking of particles, leading to lower sintering temperatures and reduced deformation of the 3D object during sintering. An embodiment of the system comprises means for adjusting a volume of a powder metered onto a top surface of the powder bed to produce an adjusted metered volume and means for spreading the adjusted metered volume to produce a smooth volume for forming a smooth layer of the powder with controlled packing density across the top surface of the powder bed. The controlled packing density enables uniform shrinkage, without warping, of the 3D object during sintering to produce higher quality 3D printed objects.

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
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B22F 3/16 - Both compacting and sintering in successive or repeated steps
  • B22F 3/18 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor by using pressure rollers
  • B22F 3/24 - After-treatment of workpieces or articles
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 10/37 - Process control of powder bed aspects, e.g. density
  • B22F 12/52 - Hoppers
  • B22F 12/57 - Metering means
  • B22F 12/63 - 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
  • B29C 64/214 - Doctor blades
  • B29C 64/218 - Rollers
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 64/329 - Feeding using hoppers
  • B29C 64/343 - Metering
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • H05K 3/10 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
  • H05K 3/12 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using printing techniques to apply the conductive material
  • B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • 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
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

63.

THERMAL DEBINDING TECHNIQUES FOR ADDITIVE MANUFACTURING AND RELATED SYSTEMS AND METHODS

      
Application Number 17097648
Status Pending
Filing Date 2020-11-13
First Publication Date 2021-05-20
Owner Desktop Metal, Inc. (USA)
Inventor
  • Reidy, John
  • Craven, Christopher
  • Tuncer, Nihan
  • Bose, Animesh
  • Barbati, Alexander C.
  • Fulop, Ricardo
  • Kernan, Brian D.
  • Schofalvi, Karl-Heinz

Abstract

Techniques for debinding additively fabricated parts are described that do not require solvent debinding or catalytic debinding, and that may be performed using only thermal debinding in a furnace. As a result, in at least some cases debinding and sintering may take place sequentially within a single furnace. In some embodiments, the techniques may utilize particular materials as binders that allow for a thermal debinding process that does not negatively affect the parts.

IPC Classes  ?

  • C08L 23/12 - Polypropene
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B28B 1/00 - Producing shaped articles from the material
  • B22F 10/10 - Formation of a green body
  • B22F 10/64 - Treatment of workpieces or articles after build-up by thermal means
  • 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

64.

Systems and methods for powder recovery, cleaning, and blending, for additive manufacturing

      
Application Number 17098739
Grant Number 11718033
Status In Force
Filing Date 2020-11-16
First Publication Date 2021-05-20
Grant Date 2023-08-08
Owner Desktop Metal, Inc. (USA)
Inventor
  • Myerberg, Jonah
  • Schmitt, Peter

Abstract

A method of recycling build material powder including collecting in a keg an amount of excess build material powder during the additive manufacturing of a part cake. The part cake and keg are transferred to a de-powdering station. The part cake is de-powdered to release a mixture of reusable powder and contaminants. The mixture is sieved to remove the contaminants and deposit the reusable powder to the keg.

IPC Classes  ?

  • B29C 64/357 - Recycling
  • B29C 64/35 - Cleaning
  • 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
  • B07B 9/00 - Combinations of apparatus for screening or sifting or for separating solids from solids using gas currents; General arrangement of plant, e.g. flow sheets

65.

Three-dimensional printer

      
Application Number 29709057
Grant Number D0919679
Status In Force
Filing Date 2019-10-10
First Publication Date 2021-05-18
Grant Date 2021-05-18
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin
  • Kramer, Matthew

66.

BINDER COMPOSITIONS FOR ADDITIVE MANUFACTURING COMPRISING LOW MOLECULAR WEIGHT POLYMERS INCLUDING ACRYLIC ACID REPEAT UNITS

      
Application Number 17075355
Status Pending
Filing Date 2020-10-20
First Publication Date 2021-05-13
Owner DESKTOP METAL, INC. (USA)
Inventor
  • Renner, Christopher Benjamin
  • Rushkin, Ilya L.
  • Sachs, Emanuel M.

Abstract

Methods of additive manufacturing, binder compositions for additive manufacturing, and articles produced by and/or associated with methods of additive manufacturing are generally described.

IPC Classes  ?

  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing

67.

Furnace

      
Application Number 29712194
Grant Number D0918355
Status In Force
Filing Date 2019-11-06
First Publication Date 2021-05-04
Grant Date 2021-05-04
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin

68.

Method for Reducing Layer Shifting and Smearing During 3D Printing

      
Application Number 17135120
Status Pending
Filing Date 2020-12-28
First Publication Date 2021-04-22
Owner Desktop Metal, Inc. (USA)
Inventor
  • Hudelson, George
  • Legendre, Alexander Nicholas
  • Wiebe, Kelvin

Abstract

An additive manufacturing system, and corresponding method, prints a sacrificial component using a 3D printing system that includes a spreading mechanism for spreading unbound powder to form layers of a powder bed and a printing mechanism for jetting binder fluid into the unbound powder to form the sacrificial component. The system forms the sacrificial component with a feature that provides a resistive force to a shear force imposed by the spreading mechanism during the spreading. The system prints a part with the 3D printing system in a coupled arrangement with the sacrificial component. The coupled arrangement in combination with the resistive force is sufficient to immobilize each printed layer of the part to resist the shear force imposed by the spreading mechanism during spreading of the unbound powder above each printed layer of the part. After printing, and before or after post-processing, the part and sacrificial component are separated.

IPC Classes  ?

  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • 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 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • 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
  • B28B 1/00 - Producing shaped articles from the material
  • B28B 11/24 - Apparatus or processes for treating or working the shaped articles for curing, setting or hardening
  • B28B 17/00 - SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER - Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping

69.

ADDITIVE FABRICATION WITH INFILTRATION BARRIERS

      
Application Number 17251806
Status Pending
Filing Date 2019-07-12
First Publication Date 2021-04-22
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sercombe, Timothy
  • Benn, Ellen
  • Gibson, Michael Andrew
  • Tuncer, Nihan

Abstract

A method of maintaining part geometry fidelity during infiltration of a metallic preform. The preform and an infiltration barrier are formed, either independently or together during an additive manufacturing process. The infiltration barrier prevents infiltrant from bleeding out from the preform where it is present, thus protecting fine geometries that would otherwise be filled with infiltrant.

IPC Classes  ?

  • B22F 10/60 - Treatment of workpieces or articles after build-up
  • B28B 1/00 - Producing shaped articles from the material
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

70.

SYSTEMS AND METHODS FOR REDUCING ARCING IN VACUUM OR PARTIAL VACUUM FURNACE USING DC POWER

      
Application Number 17067974
Status Pending
Filing Date 2020-10-12
First Publication Date 2021-04-15
Owner DESKTOP METAL, INC. (USA)
Inventor
  • Fontana, Richard Remo
  • Fay, Leon

Abstract

A sintering furnace may include a furnace chamber and a retort located within the furnace chamber that receives a part to be heated. The furnace may also include one or more heating elements positioned around the retort and a power controller including power modules connected in series. The power modules may be operably connected to the one or more heating elements and may provide a direct current (DC) power output. A controller may selectively control the power modules to supply power to the one or more heating elements.

IPC Classes  ?

  • F27B 5/04 - Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated adapted for treating the charge in vacuum or special atmosphere
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted 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
  • F27B 5/14 - Arrangements of heating devices
  • F27D 7/06 - Forming or maintaining special atmospheres or vacuum within heating chambers
  • F27D 11/04 - Ohmic resistance heating with direct passage of current through the material being heated
  • F27B 5/18 - Arrangement of controlling, monitoring, alarm or like devices

71.

Compound furnace

      
Application Number 17018334
Grant Number 11766718
Status In Force
Filing Date 2020-09-11
First Publication Date 2021-03-18
Grant Date 2023-09-26
Owner Desktop Metal, Inc. (USA)
Inventor Woodard, Nathan

Abstract

A compound sintering furnace with managed contamination for debinding and sintering parts. An inner insulation layer is disposed within an outer insulation layer and has an internal hot face surrounding a work zone. A sealed housing surrounds the inner insulation layer and is composed of a refractory material capable of withstanding a service temperature greater than a debinding temperature and less than a sintering temperature. An outer heater system is configured to heat at least a portion of the sealed housing and externally heat the inner insulation layer to, in conjunction with an inner heater system, heat the work zone to the debinding temperature, and inhibit condensation of a binder within and upon the inner insulation layer during a debinding process. The inner heater system is configured to internally heat the inner insulation and heat the work zone to the sintering temperature.

IPC Classes  ?

  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B22F 3/10 - Sintering only
  • F27B 5/04 - Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated adapted for treating the charge in vacuum or special atmosphere
  • F27B 5/14 - Arrangements of heating devices
  • B22F 3/22 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor for producing castings from a slip
  • F27D 7/02 - Supplying steam, vapour, gases, or liquids
  • F27B 5/06 - Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated - Details, accessories, or equipment peculiar to furnaces of these types
  • F27D 1/18 - Door frames; Doors, lids, removable covers

72.

Method for forming 3D printed objects with multi-layer rafts which optimize shrinkage

      
Application Number 17018466
Grant Number 11554552
Status In Force
Filing Date 2020-09-11
First Publication Date 2021-03-18
Grant Date 2023-01-17
Owner Desktop Metal, Inc. (USA)
Inventor
  • Tobia, Jay
  • Preston, Aaron M.
  • Barbati, Alexander C.

Abstract

Systems and methods for forming an object using additive manufacturing. One method includes receiving a digital model of the object, predicting a shrinking characteristic or receiving a predicted shrinking characteristic of the object that will occur during thermal processing of the object, once formed, and generating, based on the shrinking characteristic of the object, instructions for forming a raft on which the object will be formed. The instructions for forming the raft are configured to form a raft having a shrinking characteristic that reflects the shrinking characteristic of the object.

IPC Classes  ?

  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B29C 64/209 - Heads; Nozzles
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B28B 1/00 - Producing shaped articles from the material
  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • 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

73.

Techniques for depowdering additively fabricated parts through fluid immersion and related systems and methods

      
Application Number 16999210
Grant Number 11759859
Status In Force
Filing Date 2020-08-21
First Publication Date 2021-03-04
Grant Date 2023-09-19
Owner Desktop Metal, Inc. (USA)
Inventor
  • Go, Jamison
  • Sachs, Daniel
  • Nick, Robert J.
  • Myerberg, Jonah Samuel
  • Goldblatt, Michael

Abstract

Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from additively fabricated parts through liquid immersion of the parts. Motion of the liquid, such as liquid currents, may dislodge or otherwise move powder away from additively fabricated parts to which it is adhered or otherwise proximate to. The liquid may also provide a vehicle to carry away powder from the additively fabricated parts. Removed powder may be filtered or otherwise separated from the liquid to allow recirculation of the liquid to the parts and/or to enable re-use of the powder in subsequent additive fabrication processes. Techniques for depowdering through liquid immersion may be automated, thereby mitigating challenges associated with manual depowdering operations.

IPC Classes  ?

  • B22F 3/24 - After-treatment of workpieces or articles
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B08B 3/10 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
  • B08B 3/04 - Cleaning involving contact with liquid
  • B08B 3/12 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
  • B08B 3/14 - Removing waste, e.g. labels, from cleaning liquid
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder

74.

Techniques for depowdering additively fabricated parts through vibratory motion and related systems and methods

      
Application Number 16989149
Grant Number 11833585
Status In Force
Filing Date 2020-08-10
First Publication Date 2021-02-25
Grant Date 2023-12-05
Owner Desktop Metal, Inc. (USA)
Inventor
  • Go, Jamison
  • Shydo, Jr., Robert Michael
  • Sachs, Emanuel M.
  • Santorella, Michael
  • Zero, Midnight
  • Myerberg, Jonah Samuel
  • Gabay, Joseph
  • Von Loesecke, Jeffrey
  • Mccalmont, Alexander K.

Abstract

Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts through vibration of the powder, the parts, and/or structures mechanically connected to the powder and/or parts. For instance, the application of vibration may dislodge, aerate and/or otherwise increase the flowability of regions of the powder, thereby making it easier to remove the powder with a suitable means. Techniques for depowdering through vibration may be automated, thereby mitigating challenges associated with manual depowdering operations.

IPC Classes  ?

  • B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic 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

75.

Binder composition for additive manufacturing

      
Application Number 16998527
Grant Number 11945943
Status In Force
Filing Date 2020-08-20
First Publication Date 2021-02-25
Grant Date 2024-04-02
Owner Desktop Metal, Inc. (USA)
Inventor
  • Renner, Christopher Benjamin
  • Rushkin, Ilya L.
  • Nick, Robert J.
  • Sachs, Emanuel M.

Abstract

Methods of additive manufacturing, binder compositions for additive manufacturing, and articles produced by and/or associated with methods of additive manufacturing are generally described.

IPC Classes  ?

  • B33Y 10/00 - Processes of additive manufacturing
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 1/103 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing
  • C08L 33/02 - Homopolymers or copolymers of acids; Metal or ammonium salts thereof

76.

Techniques for depowdering additively fabricated parts via gas flow and related systems and methods

      
Application Number 16983138
Grant Number 11951515
Status In Force
Filing Date 2020-08-03
First Publication Date 2021-02-18
Grant Date 2024-04-09
Owner Desktop Metal, Inc. (USA)
Inventor
  • Go, Jamison
  • Santorella, Michael
  • Myerberg, Jonah Samuel
  • Mccambridge, Matthew
  • Legendre, Alexander
  • Gabay, Joseph
  • Nick, Robert J.
  • Goldblatt, Michael

Abstract

Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts by directing gas onto, or near to, the powder. While fragile green parts, such as green parts produced by binder jetting, may be fragile with respect to scraping or impacts, such parts may nonetheless be resistance to damage from directed gas, even if directed at a high pressure. Techniques for depowdering through directed application of gas may be automated, thereby mitigating challenges associated with manual depowdering operations.

IPC Classes  ?

  • B08B 5/02 - Cleaning by the force of jets, e.g. blowing-out cavities
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B22F 3/10 - Sintering only
  • 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

77.

Methods and systems for condensing a vapor on a powder bed

      
Application Number 16924872
Grant Number 11717887
Status In Force
Filing Date 2020-07-09
First Publication Date 2021-01-14
Grant Date 2023-08-08
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Emanuel M.
  • Hoisington, Paul A.
  • Fontana, Richard Remo
  • Go, Jamison
  • Johnson, Joseph
  • Hudelson, George
  • Lockwood, Cassia
  • Goldblatt, Michael

Abstract

A method is provided for printing a three-dimensional object. The method comprises, depositing a layer of metal powder onto a powder bed of a three-dimensional printer. A liquid is heated to generate a vapor. The liquid is removed from the vapor to dry the vapor by heating the vapor above a condensation temperature of the liquid. The dry vapor is deposited onto the powder bed of the three-dimensional printer.

IPC Classes  ?

  • B22F 3/10 - Sintering only
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • 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

78.

Systems and methods for growth-based design

      
Application Number 16373246
Grant Number 11281820
Status In Force
Filing Date 2019-04-02
First Publication Date 2020-10-08
Grant Date 2022-03-22
Owner Desktop Metal, Inc. (USA)
Inventor
  • Roberts, Andrew Fiske
  • Gomez, Christian

Abstract

Systems and methods are disclosed for generating designs for mechanical parts in a computer aided design (CAD) context. One method includes generating a model of a mechanical part, the model including one or more cells, wherein each cell is comprised of a plurality of parameterized representations, each of the plurality of parameterized representations representing a material property; determining, for each cell, a cell-specific parameter value for each of the parameterized representations; comparing, for each cell, each of the cell-specific parameter values to a corresponding threshold parameter value associated with each of the representations of the material properties; and generating at least one additional cell or removing at least one of the one or more cells based on the comparison of each cell-specific parameter value to the corresponding threshold parameter value.

IPC Classes  ?

  • G06F 30/17 - Mechanical parametric or variational design
  • G06T 19/20 - Editing of 3D images, e.g. changing shapes or colours, aligning objects or positioning parts

79.

Additive fabrication of sinterable metallic parts via application of directed energy

      
Application Number 16824987
Grant Number 11618212
Status In Force
Filing Date 2020-03-20
First Publication Date 2020-09-24
Grant Date 2023-04-04
Owner Desktop Metal, Inc. (USA)
Inventor
  • Myerberg, Jonah Samuel
  • Hart, Anastasios John

Abstract

According to some aspects, techniques are provided for fabricating sinterable metallic parts through the application of directed energy to a build material. In particular, applying energy to a build material comprising a polymer mixed with a metal powder may cause the polymer to form a cohesive structure with the metal powder. As a result, the polymer acts as a “glue” to produce a metallic green part without local melting of the metal. The green part may subsequently be sintered to remove the polymer and produce a fully dense metal part. Optionally, a step of debinding may also be performed prior to, or simultaneously with, sintering.

IPC Classes  ?

  • 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 64/264 - Arrangements for irradiation
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29K 91/00 - Use of waxes as moulding material
  • B29K 23/00 - Use of polyalkenes as moulding material

80.

Debinder

      
Application Number 29709629
Grant Number D0893567
Status In Force
Filing Date 2019-10-16
First Publication Date 2020-08-18
Grant Date 2020-08-18
Owner Desktop Metal, Inc. (USA)
Inventor
  • Cumming, Justin
  • Schmitt, Peter
  • Fishman, Alex
  • Behar, Yves
  • Heiman, Brandon

81.

Furnace

      
Application Number 29709623
Grant Number D0892286
Status In Force
Filing Date 2019-10-16
First Publication Date 2020-08-04
Grant Date 2020-08-04
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin
  • Fishman, Alex
  • Fulop, Ric
  • Chin, Rick
  • Myerberg, Jonah Samuel
  • Behar, Yves
  • Heiman, Brandon

82.

Thermal bridge

      
Application Number 29646226
Grant Number D0881823
Status In Force
Filing Date 2018-05-02
First Publication Date 2020-04-21
Grant Date 2020-04-21
Owner Desktop Metal, Inc. (USA)
Inventor
  • Clowes, Christina
  • Dwyer, Matthew
  • White, Douglas

83.

Base plate in additive manufacturing

      
Application Number 16494680
Grant Number 11554418
Status In Force
Filing Date 2018-03-16
First Publication Date 2020-04-02
Grant Date 2023-01-17
Owner Desktop Metal, Inc. (USA)
Inventor Gibson, Michael A.

Abstract

Assemblies fabricated by additive manufacturing include an object and a base plate providing support to the object during the manufacturing process. The geometry of the base plate is defined to optimize space and material constraints. During sintering, the base plate is reduced in area in a manner complementing the reduction in the footprint of the object, preserving the fidelity of the finished object.

IPC Classes  ?

  • B22F 10/10 - Formation of a green body
  • B33Y 10/00 - Processes of additive manufacturing
  • 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
  • B29K 505/00 - Use of metals, their alloys or their compounds, as filler

84.

Debinding of 3D objects

      
Application Number 16561628
Grant Number 11413684
Status In Force
Filing Date 2019-09-05
First Publication Date 2020-02-27
Grant Date 2022-08-16
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Michael A.
  • Barbati, Alexander C.

Abstract

3D-printed parts may include binding agents to be removed following an additive manufacturing process. A debinding process removes the binding agents by immersing the part in a solvent bath causing chemical dissolution of the binding agents. The time of exposure of the 3D-printed part to the solvent is determined based on the geometry of the part, wherein the geometry is applied to predict the diffusion of the solvent through the 3D-printed part. The 3D-printed part is then immersed in the solvent bath to remove the binding agent, and is removed from the solvent bath after the time of exposure.

IPC Classes  ?

  • B22F 3/10 - Sintering only
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • 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 64/35 - Cleaning
  • B22F 10/20 - Direct sintering or melting
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • B29C 64/357 - Recycling
  • B08B 3/08 - Cleaning involving contact with liquid the liquid having chemical or dissolving effect
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor
  • 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
  • B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
  • B22F 10/30 - Process control
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • 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
  • G01B 21/08 - Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness

85.

DEBINDING OF 3D OBJECTS

      
Application Number 16561689
Status Pending
Filing Date 2019-09-05
First Publication Date 2020-02-27
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Michael A.
  • Barbati, Alexander C.

Abstract

3D-printed parts may include binding agents to be removed following an additive manufacturing process. A debinding process removes the binding agents by immersing the part in a solvent bath causing chemical dissolution of the binding agents. The time of exposure of the 3D-printed part to the solvent is determined based on the geometry of the part, wherein the geometry is applied to predict the diffusion of the solvent through the 3D-printed part. The 3D-printed part is then immersed in the solvent bath to remove the binding agent, and is removed from the solvent bath after the time of exposure.

IPC Classes  ?

  • B22F 3/10 - Sintering only
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • 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 64/35 - Cleaning
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B22F 3/105 - Sintering only by using electric current, laser radiation or plasma

86.

Debinder for 3D objects

      
Application Number 16666604
Grant Number 11407027
Status In Force
Filing Date 2019-10-29
First Publication Date 2020-02-27
Grant Date 2022-08-09
Owner Desktop Metal, Inc. (USA)
Inventor
  • Jepeal, Daniel R.
  • Dresens, Paul E.

Abstract

A debinder provides for debinding printed green parts in an additive manufacturing system. The debinder can include a storage chamber, a process chamber, a distill chamber, a waste chamber, and a condenser. The storage chamber stores a liquid solvent for debinding the green part. The process chamber debinds the green part using a volume of the liquid solvent transferred from the storage chamber. The distill chamber collects a solution drained from the process chamber and produces a solvent vapor from the solution. The condenser condenses the solvent vapor to the liquid solvent and transfer the liquid solvent to the storage chamber. The waste chamber collects a waste component of the solution.

IPC Classes  ?

  • B22F 3/10 - Sintering only
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B01D 5/00 - Condensation of vapours; Recovering volatile solvents by condensation
  • B29C 64/30 - Auxiliary operations or equipment
  • B29C 64/307 - Handling of material to be used in 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 64/35 - Cleaning
  • B01D 3/02 - Distillation or related exchange processes in which liquids are contacted with gaseous media, e.g. stripping in boilers or stills
  • C04B 35/638 - Removal thereof
  • B29C 64/357 - Recycling
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29K 505/00 - Use of metals, their alloys or their compounds, as filler
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B22F 10/10 - Formation of a green body

87.

System and method for moving a rod of build material using a pusher in a 3D printing system

      
Application Number 16580785
Grant Number 11097477
Status In Force
Filing Date 2019-09-24
First Publication Date 2020-01-16
Grant Date 2021-08-24
Owner Desktop Metal, Inc. (USA)
Inventor
  • Burnham, Richard
  • Laplante, John
  • Preston, Aaron

Abstract

A system and corresponding method to move a rod of build material in a three-dimensional (3D) printing system uses a pusher. The rod of build material has distal and proximal ends relative to an extrusion head. The distal and proximal ends having distal and proximal end surfaces, respectively. The pusher engages with the rod and applies an axial force to at least a portion of the distal end surface of the rod for at least a portion of a path the rod travels toward the extrusion head. The axial force actuates the rod of build material without alteration, such as by shaving, fracturing, or otherwise deforming the rod of build material.

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
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • 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 64/393 - 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/205 - Means for applying layers
  • B29C 64/227 - Driving means
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/321 - Feeding
  • B29C 48/475 - Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using pistons, accumulators or press rams
  • B29C 64/141 - Processes of additive manufacturing using only solid materials

88.

System and method for moving a rod of build material using a pusher in a 3D printing system

      
Application Number 16580827
Grant Number 11097479
Status In Force
Filing Date 2019-09-24
First Publication Date 2020-01-16
Grant Date 2021-08-24
Owner Desktop Metal, Inc. (USA)
Inventor
  • Burnham, Richard
  • Laplante, John
  • Preston, Aaron

Abstract

A system and corresponding method to move a rod of build material in a three-dimensional (3D) printing system uses a pusher. The rod of build material has distal and proximal ends relative to an extrusion head. The distal and proximal ends having distal and proximal end surfaces, respectively. The pusher engages with the rod and applies an axial force to at least a portion of the distal end surface of the rod for at least a portion of a path the rod travels toward the extrusion head. The axial force actuates the rod of build material without alteration, such as by shaving, fracturing, or otherwise deforming the rod of build material.

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
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • 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 64/393 - 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/205 - Means for applying layers
  • B29C 64/227 - Driving means
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/321 - Feeding
  • B29C 48/475 - Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using pistons, accumulators or press rams
  • B29C 64/141 - Processes of additive manufacturing using only solid materials

89.

System and method for moving a rod of build material using a pusher in a 3D printing system

      
Application Number 16580818
Grant Number 11097478
Status In Force
Filing Date 2019-09-24
First Publication Date 2020-01-16
Grant Date 2021-08-24
Owner Desktop Metal, Inc. (USA)
Inventor
  • Burnham, Richard
  • Laplante, John
  • Preston, Aaron

Abstract

A system and corresponding method to move a rod of build material in a three-dimensional (3D) printing system uses a pusher. The rod of build material has distal and proximal ends relative to an extrusion head. The distal and proximal ends having distal and proximal end surfaces, respectively. The pusher engages with the rod and applies an axial force to at least a portion of the distal end surface of the rod for at least a portion of a path the rod travels toward the extrusion head. The axial force actuates the rod of build material without alteration, such as by shaving, fracturing, or otherwise deforming the rod of build material.

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
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • 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 64/393 - 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/205 - Means for applying layers
  • B29C 64/227 - Driving means
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/321 - Feeding
  • B29C 48/475 - Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using pistons, accumulators or press rams
  • B29C 64/141 - Processes of additive manufacturing using only solid materials

90.

Managing powder mobility in binder jetting for additive manufacturing

      
Application Number 16576465
Grant Number 10933582
Status In Force
Filing Date 2019-09-19
First Publication Date 2020-01-09
Grant Date 2021-03-02
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Emanuel Michael
  • Hudelson, George
  • Hoisington, Paul A.
  • Renner, Christopher Benjamin
  • Vaillancourt, Keith Roy
  • Moynihan, Edward Russell

Abstract

Devices, systems, and methods are directed to the use of vapor phase change in binder jetting processes for forming three-dimensional objects. In general, a vapor of a first fluid may be directed to a layer of a powder spread across a build volume. The vapor may condense to reduce mobility of the particles of the powder of the layer. For example, the condensing vapor may reduce the likelihood of particle ejection from the layer and, thus, may reduce the likelihood of clogging or otherwise degrading a printhead used to jet a second fluid (e.g., a binder) to the layer. Further, or instead, the condensing vapor may increase the density of the powder in the layer which, when repeated over a plurality of layers forming a three-dimensional object, may reduce the likelihood of slumping of the part during sintering.

IPC Classes  ?

  • 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B28B 1/00 - Producing shaped articles from the material
  • B29C 64/364 - Conditioning of environment
  • B29C 64/371 - Conditioning of environment using an environment other than air, e.g. inert gas
  • 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 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 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/30 - Auxiliary operations or equipment
  • B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
  • B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties

91.

Method of forming an object using 3D printing

      
Application Number 16509070
Grant Number 11420254
Status In Force
Filing Date 2019-07-11
First Publication Date 2020-01-09
Grant Date 2022-08-23
Owner Desktop Metal, Inc. (USA)
Inventor
  • Brzezinski, Tomek
  • Gibson, Michael A.
  • Kelly, Michael

Abstract

A 3D printer includes a build plate providing a surface on which an object is printed. Prior to printing, a sheet is fixed to the surface of the build plate. The sheet is composed of a material that adheres to a binder component of the feedstock used to print the object. During printing, the first layer of the printed object forms a bond with the sheet, which secures the location of the first layer and resists movement of the object during printing. Following printing and the object gaining sufficient rigidity, the object and sheet can be removed together from the printer. The sheet may then be peeled from the object, and the object can undergo debinding and/or sintering to create a finished object.

IPC Classes  ?

  • B22F 3/10 - Sintering only
  • B22F 3/24 - After-treatment of workpieces or articles
  • B29C 64/223 - Foils or films, e.g. for transferring layers of building material from one working station to another
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B22F 10/10 - Formation of a green body
  • B22F 10/12 - Formation of a green body by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
  • B22F 1/10 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • 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
  • B22F 1/103 - Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent

92.

Debinding of 3D objects

      
Application Number 16561568
Grant Number 10654102
Status In Force
Filing Date 2019-09-05
First Publication Date 2020-01-02
Grant Date 2020-05-19
Owner Desktop Metal, Inc. (USA)
Inventor
  • Gibson, Michael A.
  • Barbati, Alexander C.

Abstract

3D-printed parts may include binding agents to be removed following an additive manufacturing process. A debinding process removes the binding agents by immersing the part in a solvent bath causing chemical dissolution of the binding agents. The time of exposure of the 3D-printed part to the solvent is determined based on the geometry of the part, wherein the geometry is applied to predict the diffusion of the solvent through the 3D-printed part. The 3D-printed part is then immersed in the solvent bath to remove the binding agent, and is removed from the solvent bath after the time of exposure.

IPC Classes  ?

  • B22F 3/10 - Sintering only
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • 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 64/35 - Cleaning
  • B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • B29C 64/357 - Recycling
  • B08B 3/08 - Cleaning involving contact with liquid the liquid having chemical or dissolving effect
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor
  • 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
  • B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
  • 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
  • G01B 21/08 - Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness

93.

Method of forming multi-layer sintering object support structure

      
Application Number 16436271
Grant Number 11511347
Status In Force
Filing Date 2019-06-10
First Publication Date 2019-12-12
Grant Date 2022-11-29
Owner Desktop Metal, Inc. (USA)
Inventor Gibson, Michael A.

Abstract

Support substrates are used in certain additive fabrication processes to permit processing of an object. For additive fabrication processes with materials that are sintered into a final part, a multi-layer support substrate of interleaved support and interface layers is fabricated to support an object while reducing an impact of friction on shrinkage of the part during the sintering process.

IPC Classes  ?

  • B22F 10/10 - Formation of a green body
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/141 - Processes of additive manufacturing using only solid materials
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B22F 7/00 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting
  • B28B 1/00 - Producing shaped articles from the material
  • B29K 505/00 - Use of metals, their alloys or their compounds, as filler

94.

Debinder for 3D printed objects

      
Application Number 16540725
Grant Number 11235386
Status In Force
Filing Date 2019-08-14
First Publication Date 2019-12-05
Grant Date 2022-02-01
Owner Desktop Metal, Inc. (USA)
Inventor
  • Jepeal, Daniel R.
  • Dresens, Paul E.

Abstract

A debinder provides for debinding printed green parts in an additive manufacturing system. The debinder can include a storage chamber, a process chamber, a distill chamber, a waste chamber, and a condenser. The storage chamber stores a liquid solvent for debinding the green part. The process chamber debinds the green part using a volume of the liquid solvent transferred from the storage chamber. The distill chamber collects a solution drained from the process chamber and produces a solvent vapor from the solution. The condenser condenses the solvent vapor to the liquid solvent and transfer the liquid solvent to the storage chamber. The waste chamber collects a waste component of the solution.

IPC Classes  ?

  • B22F 3/10 - Sintering only
  • B29C 64/30 - Auxiliary operations or equipment
  • B01D 5/00 - Condensation of vapours; Recovering volatile solvents by condensation
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • 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
  • B29C 64/35 - Cleaning
  • B01D 3/02 - Distillation or related exchange processes in which liquids are contacted with gaseous media, e.g. stripping in boilers or stills
  • C04B 35/638 - Removal thereof
  • B29C 64/357 - Recycling
  • B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29K 505/00 - Use of metals, their alloys or their compounds, as filler
  • B22F 10/10 - Formation of a green body

95.

Debinder

      
Application Number 29617190
Grant Number D0868148
Status In Force
Filing Date 2017-09-12
First Publication Date 2019-11-26
Grant Date 2019-11-26
Owner Desktop Metal, Inc. (USA)
Inventor
  • Cumming, Justin
  • Schmitt, Peter
  • Fishman, Alex
  • Behar, Yves
  • Heiman, Brandon

96.

Furnace

      
Application Number 29601454
Grant Number D0868228
Status In Force
Filing Date 2017-04-21
First Publication Date 2019-11-26
Grant Date 2019-11-26
Owner Desktop Metal, Inc. (USA)
Inventor
  • Schmitt, Peter
  • Cumming, Justin
  • Fishman, Alex
  • Fulop, Ric
  • Chin, Rick
  • Myerberg, Jonah Samuel
  • Behar, Yves
  • Heiman, Brandon

97.

Automated de-powdering via liquid immersion

      
Application Number 16456123
Grant Number 10543643
Status In Force
Filing Date 2019-06-28
First Publication Date 2019-11-14
Grant Date 2020-01-28
Owner Desktop Metal, Inc. (USA)
Inventor
  • Sachs, Daniel
  • Go, Jamison
  • Nick, Robert J.

Abstract

According to some aspects, a de-powdering subsystem for an additive fabrication system is described. The de-powdering subsystem may comprise a bath subsystem. The bath subsystem may comprise a reservoir configured to contain a liquid and to accept objects to be de-powdered into the liquid, and an agitation facility configured to cause currents within the liquid. The agitator facility may be at least one of (i) a pump configured to circulate the liquid within the reservoir, (ii) a heating element configured to generate convection currents in the liquid, and (iii) a stirrer driven through a linkage to a motor. The bath subsystem may comprise at least one ultrasonic transducer configured to apply ultrasonic vibrations to the liquid within the reservoir.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B08B 3/12 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
  • B08B 5/02 - Cleaning by the force of jets, e.g. blowing-out cavities
  • B08B 7/02 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass by distortion, beating, or vibration of the surface to be cleaned
  • 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 64/357 - Recycling
  • B22F 3/10 - Sintering only

98.

Support edifice for three-dimensional printing

      
Application Number 16403294
Grant Number 11407180
Status In Force
Filing Date 2019-05-03
First Publication Date 2019-11-07
Grant Date 2022-08-09
Owner Desktop Metal, Inc. (USA)
Inventor
  • Moosberg, Mats
  • Barbati, Alexander C.

Abstract

This invention relates to three-dimensional printing. This invention in particularly relates to a method of fabricating a three-dimensional object using a support edifice and also using a mold material with structural additives. The support edifice is fabricated in the same crafting material as the final three-dimensional object in the same manner as the printing of the final three-dimensional object (mold and crafting in a layer by layer manner). This method enables the support edifice to also transform during post processing in the same manner as the final three-dimensional object, thus supporting the object until finished. The system for fabricating the object comprises a dual printhead comprising a first dispensing nozzle for depositing the filament material in a flowable fluid form and a second dispensing nozzle for depositing the crafting medium, which is in a paste form. The printhead can also include a heating system or a drying apparatus. The three-dimensional imaging process for making objects, preferably metal objects or ceramic objects, on a layer-by-layer basis under the control of a data processing system is disclosed. The printing of the three-dimensional object such as heavy objects or an object having different parts having a very thin gap or space. It is important to use different processing steps and/or material to print such three-dimensional objects. The present invention provides a solution by printing a support edifice comprising a special structural additive for the mold, and further the support edifice can be printed simultaneously while printing the mold and crafting-paste material on a layer-by-layer basis. The mold material is mixed with the structural additive. The structural additive is useful for prohibiting either fusing of the object with the support edifice, or in alternative embodiments, the fusing of one part of an object with another part of an object.

IPC Classes  ?

  • B32B 3/02 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B28B 1/00 - Producing shaped articles from the material
  • B33Y 80/00 - Products made by additive manufacturing
  • 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
  • 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
  • B28B 11/24 - Apparatus or processes for treating or working the shaped articles for curing, setting or hardening
  • B22F 10/10 - Formation of a green body
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
  • B22F 3/24 - After-treatment of workpieces or articles
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29K 509/02 - Ceramics
  • B29K 505/00 - Use of metals, their alloys or their compounds, as filler
  • B29K 507/04 - Carbon

99.

Systems and methods for calibration feedback for additive manufacturing

      
Application Number 16508782
Grant Number 10589467
Status In Force
Filing Date 2019-07-11
First Publication Date 2019-10-31
Grant Date 2020-03-17
Owner Desktop Metal, Inc. (USA)
Inventor
  • Tobia, Jay
  • Tuncer, Nihan
  • Preston, Aaron
  • Fulop, Ricardo
  • Gibson, Michael A.
  • Fontana, Richard Remo
  • Hart, Anastasios John

Abstract

Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/35 - Cleaning
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • G06F 17/50 - Computer-aided design
  • B22F 3/10 - Sintering only
  • B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B33Y 10/00 - Processes of additive manufacturing

100.

Systems and methods for calibration feedback for additive manufacturing

      
Application Number 16508882
Grant Number 11117192
Status In Force
Filing Date 2019-07-11
First Publication Date 2019-10-31
Grant Date 2021-09-14
Owner Desktop Metal, Inc. (USA)
Inventor
  • Preston, Aaron
  • Mykulowycz, Nicholas

Abstract

A camera assembly is employed in additive manufacturing to improve the fidelity of a printed object. The camera may scan the surface of a build plate of a 3D printer and an object as it is being printed to generate image data. The image data is processed to detect errors in the build plate or printed object. The printer compensates for the detected errors, which can including modifying the printer configuration and/or modifying the instructions for printing a given object. Using the updated configuration, subsequent objects may then be printed, under a corrected process, to produce an object with fidelity to an original object model.

IPC Classes  ?

  • B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
  • B22F 3/22 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor for producing castings from a slip
  • 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 64/386 - Data acquisition or data processing for additive manufacturing
  • 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 70/00 - Materials specially adapted for additive manufacturing
  • B22F 10/10 - Formation of a green body
  • B28B 1/00 - Producing shaped articles from the material
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