Patents Assigned to Thermwood Corporation
  • Apparatus and method for printing large thermoplastic parts during additive manufacturing
    Patent number: 10933586
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder, the extruder having an opening dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle in fluid communication with the gear pump for depositing the at least partially melted material.
    Type: Grant
    Filed: September 13, 2017
    Date of Patent: March 2, 2021
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal, Brian S. Smiddy, Jonathan I. Fuquay
  • METHODS AND APPARATUS FOR COMPENSATING FOR MATERIAL DISTORTION DURING ADDITIVE MANUFACTURING
    Publication number: 20210023771
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.
    Type: Application
    Filed: October 9, 2020
    Publication date: January 28, 2021
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Scott G. VAAL
  • METHODS AND APPARATUS FOR COMPRESSING MATERIAL DURING ADDITIVE MANUFACTURING
    Publication number: 20210008786
    Abstract: An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.
    Type: Application
    Filed: July 22, 2020
    Publication date: January 14, 2021
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Scott G. VAAL
  • Apparatus and methods for additive manufacturing at ambient temperature
    Patent number: 10889058
    Abstract: An exemplary additive manufacturing system may include an extruder having an opening dimensioned to receive a material. The extruder also may have a barrel and a screw within the barrel. The screw may have a diameter ranging between about 20 mm and about 150 mm and the barrel extends along a longitudinal axis. The system may include one or more heaters positioned along at least a portion of the barrel. As the material passes through the barrel, the one or more heaters may at least partially melt the material. The system may further include a gear pump in fluid communication with the barrel for receiving the at least partially melted material. Additionally, the system may include a nozzle in fluid communication with the gear pump for depositing the at least partially melted material. The system also may include a vertical worktable.
    Type: Grant
    Filed: November 7, 2019
    Date of Patent: January 12, 2021
    Assignee: Thermwood Corporation
    Inventor: Scott G. Vaal
  • APPARATUS AND METHODS FOR COMPRESSING MATERIAL DURING ADDITIVE MANUFACTURING
    Publication number: 20200398489
    Abstract: Embodiments of the present disclosure are drawn to an additive manufacturing system, which may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. An applicator head may surround at least a portion of a proximal region of the nozzle. The applicator head may include a housing, a cooling inlet for receiving a coolant into the housing, a cooling outlet configured to allow the coolant to exit the housing, and an air inlet. A roller may be mounted on the applicator head to one side of the outlet of the nozzle. The roller may include an air outlet, wherein a flow path connects the air inlet and the air outlet so that air enters the air inlet and exits the air outlet. The roller may also include a plurality of holes located on an external surface of the roller.
    Type: Application
    Filed: September 4, 2020
    Publication date: December 24, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Scott G. Vaal, Brian S. Smiddy
  • METHODS AND APPARATUS FOR COMPENSATING FOR THERMAL EXPANSION DURING ADDITIVE MANUFACTURING
    Publication number: 20200384756
    Abstract: 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: Application
    Filed: August 25, 2020
    Publication date: December 10, 2020
    Applicant: Thermwood Corporation
    Inventor: Kenneth J. SUSNJARA
  • PRINT HEAD FOR ADDITIVE MANUFACTURING
    Publication number: 20200331202
    Abstract: An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.
    Type: Application
    Filed: June 30, 2020
    Publication date: October 22, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay, Scott G. Vaal
  • Methods and apparatus for compensating for material distortion during additive manufacturing
    Patent number: 10800093
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.
    Type: Grant
    Filed: November 7, 2019
    Date of Patent: October 13, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal
  • Near net shape additive manufacturing
    Patent number: 10786944
    Abstract: 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: Grant
    Filed: November 22, 2019
    Date of Patent: September 29, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay
  • Apparatus and methods for compressing material during additive manufacturing
    Patent number: 10786946
    Abstract: Embodiments of the present disclosure are drawn to an additive manufacturing system, which may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. An applicator head may surround at least a portion of a proximal region of the nozzle. The applicator head may include a housing, a cooling inlet for receiving a coolant into the housing, a cooling outlet configured to allow the coolant to exit the housing, and an air inlet. A roller may be mounted on the applicator head to one side of the outlet of the nozzle. The roller may include an air outlet, wherein a flow path connects the air inlet and the air outlet so that air enters the air inlet and exits the air outlet. The roller may also include a plurality of holes located on an external surface of the roller.
    Type: Grant
    Filed: September 13, 2017
    Date of Patent: September 29, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal, Brian S. Smiddy
  • APPARATUS AND METHODS FOR FABRICATING COMPONENTS
    Publication number: 20200298551
    Abstract: 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: Application
    Filed: June 12, 2020
    Publication date: September 24, 2020
    Applicant: Thermwood Corporation
    Inventor: Kenneth Susnjara
  • Apparatus and method for thermal compensation during additive manufacturing
    Patent number: 10780635
    Abstract: An additive manufacturing apparatus includes an extruder and a gear pump in fluid communication with extruder. The additive manufacturing apparatus also includes a nozzle in fluid communication with the gear pump. The extruder is connected to a guide member such that at least a portion of the extruder is configured to expand and move along the guide member according to a thermal expansion of the extruder.
    Type: Grant
    Filed: October 8, 2019
    Date of Patent: September 22, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay, Scott G. Vaal
  • Methods and apparatus for compensating for thermal expansion during additive manufacturing
    Patent number: 10766244
    Abstract: 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: Grant
    Filed: September 17, 2019
    Date of Patent: September 8, 2020
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • METHODS AND APPARATUS FOR PROCESSING AND DISPENSING MATERIAL DURING ADDITIVE MANUFACTURING
    Publication number: 20200276757
    Abstract: 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: Application
    Filed: May 19, 2020
    Publication date: September 3, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Nicholas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
  • Methods and apparatus for compressing material during additive manufacturing
    Patent number: 10744709
    Abstract: An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.
    Type: Grant
    Filed: September 17, 2019
    Date of Patent: August 18, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal
  • MACHINE AND METHOD FOR FORMING ARTICLES
    Publication number: 20200254674
    Abstract: 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: Application
    Filed: April 29, 2020
    Publication date: August 13, 2020
    Applicant: Thermwood Corporation
    Inventor: Kenneth J. SUSNJARA
  • SYSTEMS AND METHODS FOR PRINTING COMPONENTS USING ADDITIVE MANUFACTURING
    Publication number: 20200247048
    Abstract: 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: Application
    Filed: April 23, 2020
    Publication date: August 6, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal, Nicolas C. Vote
  • Print head for additive manufacturing
    Patent number: 10723074
    Abstract: An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.
    Type: Grant
    Filed: January 4, 2019
    Date of Patent: July 28, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay, Scott G. Vaal
  • Apparatus and methods for fabricating components
    Patent number: 10723116
    Abstract: 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: Grant
    Filed: October 23, 2019
    Date of Patent: July 28, 2020
    Assignee: Thermwood Corporation
    Inventor: Kenneth Susnjara
  • PRINT HEAD FOR ADDITIVE MANUFACTURING
    Publication number: 20200215749
    Abstract: An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.
    Type: Application
    Filed: January 4, 2019
    Publication date: July 9, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay, Scott G. Vaal