Patents by Inventor Andrew Michael Stulc
Andrew Michael Stulc has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11926099Abstract: A system is disclosed for additively manufacturing a structure. The system may include a motion platform, a print head, and a drive. The drive may include a base connectable to the motion platform, a slipring disposed inside of the base, and a drivetrain extending between the base and the print head.Type: GrantFiled: February 18, 2022Date of Patent: March 12, 2024Assignee: Continuous Composites Inc.Inventors: Andrew Michael Stulc, Nathan Andrew Stranberg
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Patent number: 11904534Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a housing, a supply module operatively mounted to the housing and configured to hold a supply of continuous reinforcement, an impregnation module operatively mounted to the housing and configured to wet the continuous reinforcement with a matrix, and a clamping module operatively mounted to the housing downstream of the supply module relative to movement of a reinforcement through the print head. The clamping module may be configured to selectively clamp the continuous reinforcement. The additive manufacturing system may also include a controller in communication with the support and the print head and configured to coordinate operations of the support and the print head to fabricate a three-dimensional structure.Type: GrantFiled: February 24, 2021Date of Patent: February 20, 2024Assignee: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew Michael Stulc, Brock Adam Jahner, Stephen Tyler Wilson
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Patent number: 11813793Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a continuous reinforcement, a second supply configured to hold a matrix separate from the continuous reinforcement, and a wetting mechanism in separate communication with the first and second supplies and configured to discharge the continuous reinforcement wetted with the matrix. The system may also include a controller programmed to selectively pressurize the second supply to direct the matrix to the wetting mechanism.Type: GrantFiled: July 26, 2021Date of Patent: November 14, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Patent number: 11806923Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may have an outlet configured to discharge a continuous reinforcement at least partially coated in a matrix, and a device located inside the print head and configured to at least partially coat the continuous reinforcement with the matrix. The system may also include a sensor configured to generate a signal indicative of an amount of the matrix, and a controller in communication with the sensor and the device. The controller may be configured to direct a command to the device to cause the device to advance matrix toward the continuous reinforcement during passage of the continuous reinforcement through the print head, and to selectively adjust the command based on the signal.Type: GrantFiled: December 21, 2021Date of Patent: November 7, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Nathan Andrew Stranberg, Ryan C Stockett, Andrew Michael Stulc
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Patent number: 11760021Abstract: A system is disclosed for use in additively manufacturing an object. The system may have a reinforcement supply, a matrix supply, and a wetting module configured to separately receive reinforcement from the reinforcement supply and matrix from the matrix supply and to discharge the reinforcement wetted with the matrix. The wetting module may include a body forming an enclosure and having an inlet end configured to receive the reinforcement and an outlet end configured to discharge the reinforcement wetted with the matrix. The wetting module may also include a plurality of nozzles dividing the enclosure into at least a wetting chamber.Type: GrantFiled: April 5, 2022Date of Patent: September 19, 2023Assignee: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew John Overby, Andrew Michael Stulc, Stephen Tyler Wilson, Ryan C. Stocket, Brock Adam Jahner
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Publication number: 20230191697Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.Type: ApplicationFiled: February 16, 2023Publication date: June 22, 2023Applicant: Continuous Composites, Inc.Inventors: TREVOR DAVID BUDGE, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20230122355Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.Type: ApplicationFiled: November 29, 2022Publication date: April 20, 2023Applicant: Continuous Composites Inc.Inventors: TREVOR DAVID BUDGE, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Patent number: 11613080Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.Type: GrantFiled: July 26, 2021Date of Patent: March 28, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Patent number: 11541598Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.Type: GrantFiled: July 28, 2021Date of Patent: January 3, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20220339868Abstract: A system is disclosed for additively manufacturing a structure. The system may include a motion platform, a print head, and a drive. The drive may include a base connectable to the motion platform, a slipring disposed inside of the base, and a drivetrain extending between the base and the print head.Type: ApplicationFiled: February 18, 2022Publication date: October 27, 2022Applicant: Continuous Composites Inc.Inventors: Andrew Michael Stulc, Nathan Andrew Stranberg
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Publication number: 20220339872Abstract: A method is disclosed for additively manufacturing an object. The method may include extending a first module of a print head to push a tag end of material adjacent a second module during a feeding routine. The method may also include extending the second module to push against the tag end, and activating a third module to at least partially cure the tag end and thereby adhere the tag end as an anchor.Type: ApplicationFiled: April 5, 2022Publication date: October 27, 2022Applicant: Continous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew John Overby, Andrew Michael Stulc, Stephen Tyler Wilson, Ryan C. Stocket, Brock Adam Jahner, Christopher Losee
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Publication number: 20220339874Abstract: A system is disclosed for use in additively manufacturing an object. The system may have a support and a first module operatively mounted to an end of the support and configured to discharge a material during motion of the support to form an object. The system may also have a second module configured to sever the material, at least a third module configured to at least one of compact or cure the material, and an actuator configured to cause movement of the second and the at least a third modules relative to the first module.Type: ApplicationFiled: April 5, 2022Publication date: October 27, 2022Applicant: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew John Overby, Andrew Michael Stulc, Stephen Tyler Wilson, Ryan C. Stocket, Brock Adam Jahner
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Publication number: 20220339866Abstract: A print head is disclosed for use in additively manufacturing an object. The print head may have a housing, and a wetting module configured to wet a reinforcement with a liquid matrix. The print head may also include a matrix supply configured to hold a quantity of the liquid matrix and supply the liquid matrix to the wetting module.Type: ApplicationFiled: April 5, 2022Publication date: October 27, 2022Applicant: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew John Overby, Andrew Michael Stulc, Stephen Tyler Wilson, Ryan C. Stocket, Brock Adam Jahner
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Publication number: 20220339871Abstract: A system is disclosed for use in additively manufacturing an object. The system may have a reinforcement supply, a matrix supply, and a wetting module configured to separately receive reinforcement from the reinforcement supply and matrix from the matrix supply and to discharge the reinforcement wetted with the matrix. The wetting module may include a body forming an enclosure and having an inlet end configured to receive the reinforcement and an outlet end configured to discharge the reinforcement wetted with the matrix. The wetting module may also include a plurality of nozzles dividing the enclosure into at least a wetting chamber.Type: ApplicationFiled: April 5, 2022Publication date: October 27, 2022Applicant: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Andrew John Overby, Andrew Michael Stulc, Stephen Tyler Wilson, Ryan C. Stocket, Brock Adam Jahner
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Patent number: 11465348Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a supply of continuous reinforcement, an outlet configured to discharge the continuous reinforcement, and a tensioning module disposed between the supply and outlet. The tensioning module may be configured to generate a signal indicative of a tension in the continuous reinforcement. The system may also include a processor programmed to selectively cause the supply to dispense the continuous reinforcement based on the signal.Type: GrantFiled: July 26, 2021Date of Patent: October 11, 2022Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Patent number: 11420390Abstract: An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head configured to discharge a material and being operatively connected to and moveable by the support in a normal travel direction during material discharge. The print head may include a module located at a trailing side of the discharging material relative to the normal travel direction and being configured to compact the material and expose the material to a cure energy at a tool center point.Type: GrantFiled: April 7, 2020Date of Patent: August 23, 2022Assignee: Continuous Composites Inc.Inventors: Marcus Raye Vincent Brodie, Kyle Frank Cummings, Andrew Michael Stulc, Nathan Andrew Stranberg, Brock Jahner, Stephen Tyler Wilson
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Publication number: 20220118699Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head connected to and moveable by the support. The print head may have an outlet configured to discharge a continuous reinforcement at least partially coated in a matrix, and a device located inside the print head and configured to at least partially coat the continuous reinforcement with the matrix. The system may also include a sensor configured to generate a signal indicative of an amount of the matrix, and a controller in communication with the sensor and the device. The controller may be configured to direct a command to the device to cause the device to advance matrix toward the continuous reinforcement during passage of the continuous reinforcement through the print head, and to selectively adjust the command based on the signal.Type: ApplicationFiled: December 21, 2021Publication date: April 21, 2022Applicant: Continuous Composites Inc.Inventors: Trevor David BUDGE, Nathan Andrew Stranberg, Ryan C. Stockett, Andrew Michael Stulc
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Publication number: 20220080658Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a continuous reinforcement, a second supply configured to hold a matrix separate from the continuous reinforcement, and a wetting mechanism in separate communication with the first and second supplies and configured to discharge the continuous reinforcement wetted with the matrix. The system may also include a controller programmed to selectively pressurize the second supply to direct the matrix to the wetting mechanism.Type: ApplicationFiled: July 26, 2021Publication date: March 17, 2022Applicant: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20220080653Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.Type: ApplicationFiled: July 28, 2021Publication date: March 17, 2022Applicant: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson
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Publication number: 20220080659Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.Type: ApplicationFiled: July 26, 2021Publication date: March 17, 2022Applicant: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby