Patents Assigned to Thermwood Corporation
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Publication number: 20230219301Abstract: An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.Type: ApplicationFiled: March 8, 2023Publication date: July 13, 2023Applicant: Thermwood CorporationInventor: Kenneth J. SUSNJARA
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Patent number: 11628614Abstract: An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.Type: GrantFiled: March 4, 2022Date of Patent: April 18, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay
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Patent number: 11618209Abstract: An additive manufacturing apparatus an extruder configured to receive material, a work surface extending so as to define a plane for receiving one or more layers of the material, an applicator assembly secured at a downstream portion of the additive manufacturing apparatus, a nozzle connected to the applicator assembly, the nozzle being configured to receive the material from the extruder and deposit the material on the work surface, and an actuator configured to displace the work surface in a movement direction, wherein the movement direction forms an acute angle with the plane.Type: GrantFiled: March 24, 2022Date of Patent: April 4, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Brian S. Smiddy, Jonathan L. Fuquay
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Patent number: 11618218Abstract: An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.Type: GrantFiled: September 7, 2022Date of Patent: April 4, 2023Assignee: Thermwood CorporationInventor: Kenneth J. Susnjara
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Patent number: 11607845Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: GrantFiled: June 13, 2022Date of Patent: March 21, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Publication number: 20230056184Abstract: A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.Type: ApplicationFiled: October 7, 2022Publication date: February 23, 2023Applicant: Thermwood CorporationInventor: Kenneth J. SUSNJARA
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Patent number: 11554538Abstract: An additive manufacturing apparatus includes a material container having a hollow interior configured to receive a material and an extruder connected below the material container to receive the material from the material container. The additive manufacturing apparatus includes a material removal device including an actuator configured to activate the material removal device to dislodge retained material from within the hollow interior of the material container and a drain passage configured to receive the dislodged material and guide the material to an exterior of the additive manufacturing apparatus.Type: GrantFiled: July 19, 2022Date of Patent: January 17, 2023Assignee: Thermwood CorporationInventors: Brian S. Smiddy, Scott G. Vaal
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Publication number: 20220410493Abstract: An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.Type: ApplicationFiled: September 7, 2022Publication date: December 29, 2022Applicant: Thermwood CorporationInventor: Kenneth J. SUSNJARA
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Publication number: 20220362989Abstract: An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.Type: ApplicationFiled: April 28, 2022Publication date: November 17, 2022Applicant: Thermwood CorporationInventor: Kenneth J. SUSNJARA
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Patent number: 11491739Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.Type: GrantFiled: July 8, 2021Date of Patent: November 8, 2022Assignee: THERMWOOD CORPORATIONInventor: Kenneth J. Susnjara
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Patent number: 11491696Abstract: A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.Type: GrantFiled: May 17, 2021Date of Patent: November 8, 2022Assignee: THERMWOOD CORPORATIONInventor: Kenneth J. Susnjara
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Patent number: 11472108Abstract: An additive manufacturing apparatus includes a material container having a hollow interior configured to receive a material and an extruder connected below the material container to receive the material from the material container. The additive manufacturing apparatus includes a material removal device including an actuator configured to activate the material removal device to dislodge retained material from within the hollow interior of the material container and a drain passage configured to receive the dislodged material and guide the material to an exterior of the additive manufacturing apparatus.Type: GrantFiled: October 28, 2021Date of Patent: October 18, 2022Assignee: THERMWOOD CORPORATIONInventors: Brian S. Smiddy, Scott G. Vaal
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Patent number: 11465362Abstract: An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.Type: GrantFiled: June 30, 2020Date of Patent: October 11, 2022Assignee: THERMWOOD CORPORATIONInventor: Kenneth J. Susnjara
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Publication number: 20220305729Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: ApplicationFiled: June 13, 2022Publication date: September 29, 2022Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Nicolas VOTE, Robert GAESSER, Brian S. SMIDDY, Scott G. VAAL
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Publication number: 20220288915Abstract: An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.Type: ApplicationFiled: June 3, 2022Publication date: September 15, 2022Applicant: Thermwood CorporationInventor: Kenneth SUSNJARA
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Patent number: 11383438Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: GrantFiled: August 6, 2021Date of Patent: July 12, 2022Assignee: THERMWOOD CORPORATIONInventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Patent number: 11376778Abstract: An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.Type: GrantFiled: December 2, 2021Date of Patent: July 5, 2022Assignee: THERMWOOD CORPORATIONInventor: Kenneth Susnjara
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Publication number: 20220184881Abstract: An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.Type: ApplicationFiled: March 4, 2022Publication date: June 16, 2022Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Brian S. Smiddy, John Fuquay
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Patent number: 11345081Abstract: An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.Type: GrantFiled: May 17, 2021Date of Patent: May 31, 2022Assignee: THERMWOOD CORPORATIONInventor: Kenneth J. Susnjara
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Publication number: 20220111589Abstract: A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.Type: ApplicationFiled: December 22, 2021Publication date: April 14, 2022Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Scott G. VAAL, Nicolas C. VOTE