公开(公告)号：US20200324461A1

公开(公告)日：2020-10-15

申请号：US16840868

申请日：2020-04-06

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark ,  Antoni S. Gozdz

IPC: B29C64/118 ,  B29C64/321 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y70/00 ,  B29C64/295 ,  B29C64/209 ,  B29C64/393

Abstract: According to one aspect, embodiments herein provide a 3-D printer comprising a composite filament supply, a build platen, a print head comprising a composite filament ironing tip and a heater, a plurality of actuators that move the print head and the build platen relative to one another in three degrees of freedom at a printing rate, at least one linear feed mechanism that advances the composite filament at a feed rate and drives the composite filament into the print head to deposit the composite filament, and a controller configured to operate the heater to heat the composite filament ironing tip to flow matrix material among axial fiber strands within the composite filament and operate the plurality of actuators to press the composite filament ironing tip against the composite filament and reshape the composite filament against one of the build platen and a composite filament previously deposited upon the build platen.

公开(公告)号：US20200079027A1

公开(公告)日：2020-03-12

申请号：US16550979

申请日：2019-08-26

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C64/40 ,  B29C64/165 ,  B33Y10/00 ,  B22F3/11 ,  B29C31/04 ,  B29C64/245 ,  B29C64/295 ,  B29C64/118 ,  B29C64/141

Abstract: According to one aspect, embodiments herein provide a method of reducing distortion in an additively manufactured part comprising forming a shrinking platform from a composite including metal particles embedded in a first matrix, forming shrinking supports from the composite, forming a part from the composite upon the shrinking platform and shrinking supports, forming an interior structure in at least one of the shrinking platform, the shrinking supports, and the part having a plurality of chambers with interconnections therebetween, forming from the shrinking platform, the sintering supports, and the part a portable assembly, and debinding the first matrix in the portable assembly to form a portable assembly in a brown state, wherein debinding the first matrix includes penetrating a fluid debinder into the interior structure of the at least one of the shrinking platform, the shrinking supports, and the part to debind the first matrix from within the interior structure.

公开(公告)号：US20190375003A1

公开(公告)日：2019-12-12

申请号：US16427448

申请日：2019-05-31

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B22D31/00 ,  B22D11/01 ,  B22D27/00 ,  B33Y10/00 ,  B33Y30/00 ,  B22F3/105

Abstract: In molten metal jetting, where droplets of metal are jetted to 3D print a part, each layer may be traversed each successive layer with a normalizing grinding wheel or other leveling device such as a layer to level each successive layer, and/or the melt reservoir or printing chamber may be filled with an anoxic gas mix to prevent oxidation.

公开(公告)号：US10464131B2

公开(公告)日：2019-11-05

申请号：US15976009

申请日：2018-05-10

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B22F3/00 ,  B33Y10/00 ,  B33Y70/00 ,  B22F1/00 ,  B22F3/10

Abstract: Successive layers of a wall of a part are deposited to form a first access channel extending from an exterior of the part to an interior of the part, as well as to form a distribution channel connecting an interior volume of the honeycomb infill to the first access channel. A binder matrix retaining sinterable powder is debound by flowing a debinding fluid through the first access channel and the distribution channel within the interior volume of the honeycomb infill.

公开(公告)号：US20190270254A1

公开(公告)日：2019-09-05

申请号：US16419776

申请日：2019-05-22

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark ,  Rick Bryan Woodruff ,  Michelle Ling Chao

IPC: B29C64/40 ,  B29C64/165 ,  B33Y10/00 ,  B22F3/11 ,  B29C64/245 ,  B29C64/295 ,  B29C64/118 ,  B29C31/04 ,  B29C64/141

Abstract: According to one aspect, embodiments of the invention provide a method of 3D printing, comprising depositing a model material in successive layers to form a part, the model material being a metal composite including greater than 50% by volume metal powder and less than 50% by volume a first removable binder, depositing the model material in successive layers to form a support structure adjacent the part, depositing a sinterable separation material between a surface of the part and a surface of the support structure, the sinterable separation material formed from 10-40% by volume ceramic powder and greater than 50% by volume a second removable binder, debinding the first removable binder of the model material and the second removable binder of the sinterable separation material, and sintering the part, the support structure, and the sinterable separation material at a temperature profile that sinters the model material and the sinterable separation material.

公开(公告)号：US20190255612A1

公开(公告)日：2019-08-22

申请号：US16277100

申请日：2019-02-15

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B22F3/10 ,  C04B35/64 ,  F27B17/00 ,  B29C64/295

Abstract: According to one aspect, embodiments herein provide a furnace for debinding and sintering additively manufactured parts comprising a unitarily formed retort having at least one open side, a heater for heating a sintering volume within the retort to a debinding temperature and to a sintering temperature, an end cap sealing the at least one open side, a forming gas line penetrating the end cap for supplying forming gas at a flowrate, and a heat exchanger within the retort, outside the sintering volume, and adjacent a heated wall of the retort, the heat exchanger having an inlet connected to the forming gas line and an outlet to the sintering volume, wherein the heat exchanger includes a heat exchange tube length sufficient to heat the forming gas to within 20 degrees Celsius of the sintering temperature before the forming gas exits the outlet.

公开(公告)号：US10377083B2

公开(公告)日：2019-08-13

申请号：US16057721

申请日：2018-08-07

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C64/118 ,  B29C64/141 ,  B29C64/165 ,  B29C64/209 ,  B29C64/245 ,  B29C64/40 ,  B33Y10/00 ,  B29C31/04 ,  B29C64/295 ,  B29K79/00 ,  B29C70/16 ,  B29K25/00 ,  B22F3/11 ,  B22F3/105

Abstract: A method comprising forming a shrinking platform of layers of a composite, the composite including a metal particulate filler in a first matrix, forming a shrinking support of layers of the composite upon the shrinking platform, forming a first release layer of a release material upon the shrinking support, the release material including a ceramic particulate and a second matrix, and forming a part of the composite upon the shrinking support to form a portable assembly from the combined shrinking platform, shrinking support, release layer and part, wherein substantially horizontal portions of the part are vertically supported by the shrinking platform, wherein the first release layer is configured, after sintering, to separate the part from the shrinking support and to allow the part to be readily removed from the shrinking support, and wherein the shrinking support is configured to prevent the part from distorting during sintering.

公开(公告)号：US20190168461A1

公开(公告)日：2019-06-06

申请号：US16267671

申请日：2019-02-05

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C64/40 ,  B29C64/295 ,  B29C64/165 ,  B29C64/141 ,  B29C64/245 ,  B22F3/11 ,  B29C31/04 ,  B33Y10/00

CPC classification number: B29C64/40 ,  B22F3/1118 ,  B22F2003/1058 ,  B29C31/044 ,  B29C64/118 ,  B29C64/141 ,  B29C64/165 ,  B29C64/209 ,  B29C64/245 ,  B29C64/295 ,  B29C70/16 ,  B29K2025/08 ,  B29K2079/085 ,  B33Y10/00

Abstract: According to one aspect, embodiments herein provide a method of reducing distortion in an additively manufactured part comprising forming a shrinking platform from a composite including metal particles embedded in a first matrix, forming shrinking supports from the composite, forming a part from the composite upon the shrinking platform and shrinking supports, forming an interior structure in at least one of the shrinking platform, the shrinking supports, and the part having a plurality of chambers with interconnections therebetween, forming from the shrinking platform, the sintering supports, and the part a portable assembly, and debinding the first matrix in the portable assembly to form a portable assembly in a brown state, wherein debinding the first matrix includes penetrating a fluid debinder into the interior structure of the at least one of the shrinking platform, the shrinking supports, and the part to debind the first matrix from within the interior structure.

公开(公告)号：US20180257138A1

公开(公告)日：2018-09-13

申请号：US15976009

申请日：2018-05-10

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B22F3/00 ,  B22F1/00 ,  B33Y10/00 ,  B33Y70/00

Abstract: Successive layers of a wall of a part are deposited to form a first access channel extending from an exterior of the part to an interior of the part, as well as to form a distribution channel connecting an interior volume of the honeycomb infill to the first access channel. A binder matrix retaining sinterable powder is debound by flowing a debinding fluid through the first access channel and the distribution channel within the interior volume of the honeycomb infill.

公开(公告)号：US10052815B2

公开(公告)日：2018-08-21

申请号：US15892733

申请日：2018-02-09

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C64/40 ,  B29C64/165 ,  B29C64/245 ,  B29C64/295 ,  B29C64/141 ,  B33Y10/00 ,  B29C31/04 ,  B22F3/11 ,  B29C64/118 ,  B29C64/209 ,  B29C70/16 ,  B29K25/00 ,  B29K79/00

CPC classification number: B29C64/40 ,  B22F3/1118 ,  B22F2003/1058 ,  B29C31/044 ,  B29C64/118 ,  B29C64/141 ,  B29C64/165 ,  B29C64/209 ,  B29C64/245 ,  B29C64/295 ,  B29C70/16 ,  B29K2025/08 ,  B29K2079/085 ,  B33Y10/00

Abstract: A method comprising depositing a part from layers of model material including sinterable metal particles and a first binder, the part surrounding a hole, depositing a first support structure from layers of the model material within the hole, depositing a first release layer of a release material above the first support structure and within the hole, the release material including a dispersed ceramic powder and a second binder, depositing a second release layer of a release material below the first support structure and within the hole, and forming a multipiece assembly of the part, the first and second release layers, and the first support structure, wherein, during sintering, the part and first support structure are configured to densify as a whole at a uniform rate, the release material is configured to reduce to a loose ceramic powder, and the first support structure is configured to prevent distortion of the hole.