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.

公开(公告)号：US10259160B2

公开(公告)日：2019-04-16

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 ,  B29C64/165 ,  B29C64/20 ,  B29C64/209 ,  B29C64/118 ,  B29K105/12 ,  B29K307/04

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.

公开(公告)号：US20190084244A1

公开(公告)日：2019-03-21

申请号：US16057730

申请日：2018-08-07

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

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

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：US10226103B2

公开(公告)日：2019-03-12

申请号：US14988222

申请日：2016-01-05

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

IPC: B29C70/68 ,  B29C70/74 ,  B29D35/00 ,  A43D8/22 ,  A43B17/00 ,  A43B23/02 ,  B33Y10/00 ,  B33Y80/00 ,  B29C64/118 ,  B29C64/106

Abstract: A footwear insole shape is generated by supplying a core reinforced filament having a matrix material impregnating reinforcing strands aligned along the filament, as well as a fill material separately from the core reinforced filament and depositing at least one shell of fill material within an insole shape upon a print bed. The core reinforced filament is deposited to fuse to the fill material within a first reinforcing region formed with respect to the insole shape. A cutter upstream of the nozzle tip cuts the core reinforced filament, and a remainder of the core reinforced filament is deposited to complete the first reinforcing region. A nozzle tip applies pressure to continuously compact the core reinforced filament toward the insole shape as the core reinforced filament is fused to the fill material.

公开(公告)号：US20190009472A1

公开(公告)日：2019-01-10

申请号：US16108870

申请日：2018-08-22

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

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

Abstract: According to one aspect, embodiments herein provide a method for in-process inspection of a 3D printed part with a 3D printer, comprising slicing a three dimensional model to define a plurality of shell volumes, for substantially each shell volume, generating a toolpath for depositing a printing material shell corresponding to the shell volume, transmitting, together with an identification, the toolpaths defining the printing material shells for deposition by a 3D printer, receiving, together with the identification, from the 3D printer a scanned surface profile of a printing material shell, and computing a process inspection including, according to the identification, a comparison between a received scanned surface profile and a toolpath defining a printing material shell.

公开(公告)号：US20180236546A1

公开(公告)日：2018-08-23

申请号：US15961384

申请日：2018-04-24

Applicant: MARKFORGED, INC.

Inventor： Gregory Thomas Mark

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

Abstract: A method comprising supplying a first brown part and a second brown part, each of the first and second brown parts formed from a material in which more than 50 percent of powder particles of a second powdered metal have a diameter less than 10 microns, in a first mode, loading the first brown part into a fused tube, and ramping a temperature inside the fused tube at greater than 10 degrees C. per minute but less than 40 degrees C. per minute to a first sintering temperature from 500-700 degrees C., and in a second mode, loading the second brown part into the fused tube, and ramping the temperature inside the fused tube at greater than 10 degrees C. per minute but less than 40 degrees C. per minute to a second sintering tempering temperature from 1000-1200 degrees C.