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.

公开(公告)号：US20180154438A1

公开(公告)日：2018-06-07

申请号：US15862156

申请日：2018-01-04

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

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

CPC classification number: B29C64/165 ,  B22D11/01 ,  B22F1/0059 ,  B22F1/0085 ,  B22F3/008 ,  B22F3/1021 ,  B22F3/1055 ,  B22F3/1146 ,  B22F3/24 ,  B22F5/10 ,  B22F2003/1046 ,  B22F2003/1056 ,  B22F2003/1057 ,  B22F2003/1058 ,  B22F2003/244 ,  B22F2005/103 ,  B22F2998/10 ,  B22F2999/00 ,  B29C64/00 ,  B29C64/118 ,  B29C64/153 ,  B29C64/209 ,  B29C64/40 ,  B29K2103/06 ,  B29K2505/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02 ,  B33Y70/00 ,  B22F3/10 ,  B22F3/003

Abstract: In printing a sinterable part using a 3D printing model material including a binder and a ceramic or metal sintering material, a release layer intervenes between support structures and the part, each of the support structures and the part formed of the model material. The release layer includes a spherized or powdered higher melting temperature material—ceramic or high temperature metal for example, optionally deposited with a similar (primary) matrix or binder component to the model material. After sintering, the release layer may become a loose powder, permitting the supports to be easily removed.

公开(公告)号：US20170297275A1

公开(公告)日：2017-10-19

申请号：US15633824

申请日：2017-06-27

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark ,  Rick Bryan Woodruff ,  David Steven Benhaim ,  Abraham Lawrence Parangi ,  Benjamin Tsu Sklaroff

IPC: B29C70/16 ,  B33Y10/00 ,  B29K77/00 ,  B29K71/00 ,  B29K63/00 ,  B33Y50/02 ,  B33Y30/00 ,  B29K79/00 ,  B29L9/00 ,  B29K25/00

CPC classification number: B29C64/386 ,  B29C64/106 ,  B29C64/209 ,  B29C64/227 ,  B29C70/16 ,  B29K2025/08 ,  B29K2063/00 ,  B29K2071/00 ,  B29K2077/00 ,  B29K2079/085 ,  B29L2009/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: According to aspects, provided is a method for displaying a three-dimensional geometry of a part to be 3D printed, comprising receiving the geometry of a part sliced into shells or layers, displaying the shells or layers, displaying, for a shell or layer, a representation of a distribution of a isotropic fill material, displaying, for an anisotropic fill subset of the set of shells or layers, a representation of a distribution of an anisotropic fill material having an anisotropic characteristic oriented relative to a trajectory of an anisotropic fill tool path, receiving a selection, from among the displayed shells or layers, of an editing subset, the editing subset including part of the anisotropic fill subset, and regenerating, for a shell or layer of the editing subset, one of a second representation of a distribution of isotropic fill material and a second representation of a distribution of anisotropic fill material.

公开(公告)号：US20170232674A1

公开(公告)日：2017-08-17

申请号：US15436216

申请日：2017-02-17

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C67/00 ,  B29C31/08 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B29C31/04 ,  B33Y70/00

CPC classification number: B29C64/165 ,  B29C31/042 ,  B29C31/08 ,  B29C64/118 ,  B29C64/20 ,  B29C64/209 ,  B29K2105/12 ,  B29K2307/04 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y70/00

Abstract: A three dimensional printer which prints at using at least one composite material having an inherently abrasive filler or fiber material has a Mohs hardness greater than substantially 1, or a Knoop/Vickers hardness greater than substantially 300 kg/mm2, or a Rockwell C hardness at least C30, and where a nozzle tip may contact a top surface of a previously deposited line of material may have a nozzle body includes a material having a thermal conductivity at least 35 w/M-K to conduct heat to the nozzle, and a nozzle throat and/or nozzle tip each include a material having a Rockwell C hardness at least C40, to resist wear from sliding contact of the nozzle tip with the previously deposited lines of the material being printed or another previously deposited material, or from the material being printed as it is printed through the nozzle throat.