公开(公告)号：US10953609B1

公开(公告)日：2021-03-23

申请号：US15459965

申请日：2017-03-15

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C64/386 ,  B33Y50/02 ,  B29C64/393 ,  G05B19/4099 ,  B33Y10/00 ,  B29C67/00 ,  B29K105/00

Abstract: In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.

公开(公告)号：US10800108B2

公开(公告)日：2020-10-13

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 ,  B29C31/04 ,  B29C64/141 ,  B29C64/118 ,  B29K79/00 ,  B29K25/00 ,  B29C64/209 ,  B29C70/16 ,  B22F3/105

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：US10434702B2

公开(公告)日：2019-10-08

申请号：US15966654

申请日：2018-04-30

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark ,  Antoni S. Gozdz

IPC: B29C64/106 ,  B29C64/40 ,  B29C64/386 ,  B33Y10/00 ,  B33Y50/02 ,  B33Y30/00 ,  B29C70/16 ,  B29C70/20 ,  B29C64/194 ,  B29C64/188 ,  B29C64/118 ,  B29C48/92 ,  B29C48/02 ,  B29K105/08 ,  B29C69/00 ,  B29C70/54 ,  B29C48/00

Abstract: According to one aspect, embodiments of the invention provide an additively manufactured part, comprising a top portion, a bottom portion, and a plurality of compacted composite filaments arranged in layers between the top portion and the bottom portion, each compacted composite filament including one or more axial fiber strands, wherein the plurality of compacted composite filaments includes a first compacted composite filament located in a first layer and a second compacted composite filament located in a second layer, the first layer being located closer to the bottom portion than the second layer, and wherein the second compacted composite filament layer is compressed against the first compacted composite filament, forming a vertically bonded rank in which the one or more axial fiber strands of the second compacted composite filament intrudes into the first compacted composite filament.

公开(公告)号：US10377082B2

公开(公告)日：2019-08-13

申请号：US16044698

申请日：2018-07-25

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

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

Abstract: According to one aspect, embodiments herein provide a method comprising forming a shrinking platform of model material above a build plate, the model material including sinterable metal particles and a first binder, forming a support structure of the model material extending up from the shrinking platform, forming a first portion of the part from successive layers of the model material above the support structure, forming a release layer intervening between a surface of the part and an opposing surface of the support structure or between a surface of the shrinking platform and an opposing surface of the build plate, the release layer including a dispersed ceramic powder and a second binder, and supporting the part, the release layer, and the support structure upon the shrinking platform to form a platform-integrating part assembly, the support structure being configured to prevent the first portion from distorting from gravitational force during sintering.

公开(公告)号：US10099427B2

公开(公告)日：2018-10-16

申请号：US14881938

申请日：2015-10-13

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark ,  Antoni S. Gozdz

IPC: B29C67/00 ,  B29C69/00 ,  B29C70/20 ,  B29C64/106 ,  B29C64/165 ,  B29C64/20 ,  B29K101/12 ,  B29K105/10 ,  B29K105/00 ,  B33Y10/00 ,  B33Y70/00 ,  B29K105/08 ,  B29K307/04

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.

公开(公告)号：US10076875B2

公开(公告)日：2018-09-18

申请号：US15145245

申请日：2016-05-03

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark ,  Antoni S. Gozdz

IPC: B26D1/08 ,  B26D1/10 ,  B29C67/00 ,  B33Y10/00 ,  B33Y70/00 ,  B29C69/00 ,  B29C31/04 ,  B29C64/188 ,  B29C70/20 ,  B29C64/118 ,  B29C64/194 ,  B29C70/54 ,  B29C47/00 ,  B29C70/16 ,  B33Y50/02 ,  B29B15/12 ,  B29C64/106 ,  B29C64/20 ,  B29C64/386 ,  B29C64/40 ,  B29K307/04 ,  B33Y80/00 ,  B33Y30/00 ,  B29K105/08 ,  B29K105/16

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.

公开(公告)号：US20180221950A1

公开(公告)日：2018-08-09

申请号：US15943103

申请日：2018-04-02

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

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

Abstract: According to one aspect, embodiments of the invention provide a method of sintering a brown part article formed from a powdered sinterable material, comprising placing a brown part integrally formed from a first powder having a first sintering temperature in a powder bed within a crucible, the powder bed including a second powder having a second sintering temperature more than 300 degrees C. higher than the first sintering temperature, agitating the second powder to fill internal cavities of the brown part, continually resisting a weight of an unsupported portion of the brown part with the second powder, sintering the brown part at the first temperature without sintering the second powder to form a sintered part, and removing the sintered part from the powder bed. In at least one embodiment, agitating includes fluidizing the second powder by flowing a pressurized gas into the bottom of the crucible.

公开(公告)号：US10040252B2

公开(公告)日：2018-08-07

申请号：US15186651

申请日：2016-06-20

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C70/40 ,  B29C70/42 ,  B29C70/52 ,  B29C67/00 ,  B29C31/04 ,  B29C47/00 ,  B29C69/00 ,  B29C70/16 ,  B33Y10/00 ,  B33Y50/02 ,  B29C64/141 ,  B29C64/165 ,  B29C64/386 ,  B29K79/00 ,  B29K71/00 ,  B29K25/00 ,  B29K63/00 ,  B29K77/00 ,  B29K105/08 ,  B33Y70/00 ,  B29C64/209 ,  B29C64/118

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.

公开(公告)号：US20180169957A1

公开(公告)日：2018-06-21

申请号：US15892750

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 ,  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, in layers, a shrinking platform formed from a composite including metal particles embedded in a first matrix, depositing shrinking supports of the composite upon the shrinking platform, forming a separation clearance dividing at least one shrinking support into fragments, depositing, from the composite, a part upon the shrinking platform and shrinking supports, depositing a separation material intervening between the part and the shrinking supports, the separation material including a ceramic powder and a second matrix, and forming, from the shrinking platform, shrinking supports, separation material, and part, a portable platform assembly in a green state, wherein the shrinking support is configured to prevent the portable platform assembly from distorting from gravitational force during sintering of the metal particles of the assembly in a brown state, and wherein the ceramic powder of the separation material is configured to separate the shrinking support from the part following sintering.

公开(公告)号：US10000011B1

公开(公告)日：2018-06-19

申请号：US15722445

申请日：2017-10-02

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

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

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: To reduce distortion in an additively manufactured part, a shrinking platform is formed from a metal particulate filler in a debindable matrix. Shrinking supports of the same material are formed above the shrinking platform, and a desired part of the same material is formed upon them. A sliding release layer is provided below the shrinking platform of equal or larger surface area than a bottom of the shrinking platform to lateral resistance between the shrinking platform and an underlying surface. The matrix is debound sufficient to form a shape-retaining brown part assembly including the shrinking platform, shrinking supports, and the desired part. The shape-retaining brown part assembly is heated to shrink all of the components together at a same rate via atomic diffusion.