公开(公告)号：USRE50427E1

公开(公告)日：2025-05-13

申请号：US18621286

申请日：2024-03-29

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark ,  Rick Bryan Woodruff ,  Keith Durand ,  Benjamin Hodsdon Gallup ,  Michelle Ling Chao

IPC: F27B17/00 ,  B22F3/10 ,  B29C64/295 ,  B33Y30/00 ,  B33Y40/00 ,  C04B35/64 ,  B22F10/12 ,  B22F10/14 ,  B22F10/18 ,  B22F10/43 ,  B22F10/73 ,  B22F10/80 ,  B22F12/55 ,  B29C64/165

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：US20240327952A1

公开(公告)日：2024-10-03

申请号：US18502621

申请日：2023-11-06

Applicant: Markforged, Inc.

Inventor： Maxim Seleznev ,  Joseph Roy-Mayhew ,  Jessica Faust

IPC: C22C1/10 ,  B33Y10/00 ,  B33Y40/20 ,  C04B35/111 ,  C04B35/634 ,  C04B35/638 ,  C04B35/64 ,  C04B35/80 ,  C22C29/00 ,  C22C29/12

CPC classification number: C22C1/1068 ,  B33Y10/00 ,  B33Y40/20 ,  C04B35/111 ,  C04B35/634 ,  C04B35/638 ,  C04B35/64 ,  C04B35/80 ,  C22C1/1073 ,  C22C29/005 ,  C22C29/12

Abstract: Method of manufacturing a metal matrix composite part and ceramic preform assembly for use in the method. The method includes forming a ceramic preform using 3D printing, sintering the ceramic preform to form a sintered preform, introducing a liquid metal into the sintered preform to form the metal matrix composite part. The ceramic preform may be part of a ceramic preform assembly includes at least one ceramic preform and an infiltrant reservoir connected to the ceramic preform. The method may also include forming the ceramic preform assembly using 3D printing.

公开(公告)号：US11961185B2

公开(公告)日：2024-04-16

申请号：US18078235

申请日：2022-12-09

Applicant: Markforged, Inc.

Inventor： Jeffrey Lee Selden

IPC: G06T17/20 ,  B29C64/205 ,  B29C64/393 ,  G06F30/23 ,  G06T17/10 ,  B33Y30/00 ,  B33Y50/02

CPC classification number: G06T17/20 ,  B29C64/205 ,  B29C64/393 ,  G06F30/23 ,  G06T17/10 ,  B33Y30/00 ,  B33Y50/02

Abstract: A method for generating a more accurate mesh that represents a 3D printed part based on a model includes slicing the model into layers and identifying an infill-wall boundary and an exterior-interior boundary of each layer of the model. Layers of the model may be identified as critical by iterative comparison with adjacent layers. An interior voxel mesh may be constructed based on common two-dimensional reference grids imposed on the critical layers. The interior voxel mesh may be augmented to an augmented mesh and then extended to a protomesh. The protomesh may be extruded to construct the final mesh, which may be analyzed by finite element analysis. The part may be 3D printed based on the layers output by the slicing operation.

公开(公告)号：US11707781B2

公开(公告)日：2023-07-25

申请号：US16999313

申请日：2020-08-21

Applicant: MARKFORGED, INC.

Inventor： Maxim Seleznev ,  Joseph Roy-Mayhew

IPC: B22F1/05 ,  B22F3/10 ,  B33Y10/00 ,  B33Y80/00 ,  B22F10/00 ,  B33Y70/00 ,  B22F1/10 ,  B22F5/08

CPC classification number: B22F1/05 ,  B22F3/1003 ,  B22F5/08 ,  B22F10/00 ,  B33Y10/00 ,  B33Y80/00 ,  B22F1/10 ,  B22F2301/35 ,  B33Y70/00

Abstract: A material for producing a three-dimensionally printed part including a metal material and at least one sintering aid in an amount effective to give the three-dimensionally printed part a density of between about 90% and about 100% after sintering is disclosed. A method of printing a three-dimensional part including selecting a metal material, incorporating at least one sintering aid into the metal material to form a print material, and printing the three-dimensional part is also disclosed. A method of producing a sintered metal part including providing a metal material for the sintered metal part incorporating boron as a first sintering aid, incorporating phosphorus as a second sintering aid, forming the metal part in a predetermined form the metal material, and heating the formed metal part to a sintering temperature is also disclosed. Three-dimensionally printed parts are also disclosed.

公开(公告)号：US20230141459A1

公开(公告)日：2023-05-11

申请号：US17979244

申请日：2022-11-02

Applicant: Markforged, Inc.

Inventor： Bruce David Jones ,  Joseph Roy-Mayhew ,  Jessica Faust ,  Benjamin Gallup ,  David Steven Benhaim

IPC: G05B19/4099

CPC classification number: G05B19/4099 ,  G05B2219/49023

Abstract: A 3D printing apparatus and method corrects for skew in the motion components of the apparatus without the use of an independent reference object. A calibration object having features therein or thereon is printed. A user rotates the calibration object by a certain angle after it is printed. The features in/on the calibration object are measured, and an amount of skew is determined based on the measurements. In addition, a 3D printing operation is compensated based on the effects of a coefficient of thermal expansion and/or moisture absorption on dimensional changes.

公开(公告)号：US11148409B2

公开(公告)日：2021-10-19

申请号：US14942676

申请日：2015-11-16

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark ,  Antoni S. Gozdz

IPC: B33Y10/00 ,  B29C70/20 ,  B33Y70/00 ,  B29C64/118 ,  B29K77/00 ,  B29K105/10 ,  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：US10821662B2

公开(公告)日：2020-11-03

申请号：US16055483

申请日：2018-08-06

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C64/165 ,  B29C31/04 ,  B29C70/52 ,  B29C69/00 ,  B29C48/00 ,  B29C70/16 ,  B33Y10/00 ,  B33Y70/00 ,  B29C64/209 ,  B29C64/118 ,  B29C70/38 ,  B33Y30/00 ,  B29C64/321 ,  B33Y50/02 ,  B29K79/00 ,  B29K71/00 ,  B29K25/00 ,  B29K63/00 ,  B29K77/00 ,  B29L31/30 ,  B29K105/08

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：US10603841B2

公开(公告)日：2020-03-31

申请号：US15633182

申请日：2017-06-26

Applicant: MARKFORGED, INC.

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

IPC: B29C64/209 ,  B29C64/227 ,  B29C70/16 ,  B33Y10/00 ,  B33Y50/02 ,  B33Y30/00 ,  B29C64/386 ,  B29C64/106 ,  B29L9/00 ,  B29K63/00 ,  B29K71/00 ,  B29K77/00 ,  B29K79/00 ,  B29K25/00

Abstract: According to at least one aspect, embodiments of the invention provide a 3D printer comprising an anisotropic head that solidifies, along anisotropic toolpaths, fiber swaths having an anisotropic characteristic oriented relative to a trajectory of the anisotropic tool paths, an isotropic head that solidifies, along isotropic toolpaths, a substantially isotropic material, a motorized drive for moving the anisotropic head and a build plate supporting a printed part in at least three degrees of freedom, and a controller configured to control the 3D printer to build the printed part by solidifying the isotropic material along the isotropic tool paths, solidifying the anisotropic material in fiber swaths tracking a non-concentric set of anisotropic tool paths for at least a first sequence of parallel shells, solidifying the anisotropic material in fiber swaths tracking an outer concentric set of anisotropic tool paths for at least a second sequence of parallel shells.

公开(公告)号：US10391714B2

公开(公告)日：2019-08-27

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 ,  B33Y10/00 ,  B29C31/04 ,  B29K25/00 ,  B29C70/16 ,  B29K79/00 ,  B29C64/209 ,  B29C64/118

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：US20190118484A1

公开(公告)日：2019-04-25

申请号：US16044698

申请日：2018-07-25

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C64/40 ,  B29C64/245 ,  B29C31/04 ,  B29C64/141

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 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.