Patents by Inventor Brian K. Post
Brian K. Post 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: 11980939Abstract: An electromagnet alignment system for in-situ alignment of a magnetic particulate material is provided. The magnetic particulate material is dispensed through an orifice of a dispensing nozzle used for 3D printing. The system has an electromagnet assembly having a coil. The coil is configured to generate a pulsed magnetic field having a target magnetic flux intensity upon energization of the coil when the magnetic particulate material is being heated and moved through the dispensing nozzle. As a result, the magnetic particulate material is at least partially aligned with respect to a direction by the pulsed magnetic field. The system further includes a power source for implementing the energization of the coil.Type: GrantFiled: April 15, 2021Date of Patent: May 14, 2024Assignee: UT-BATTELLE, LLCInventors: Mariappan Parans Paranthaman, Brian K. Post, Brian C. Sales
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Patent number: 11752663Abstract: A print head for additive manufacturing with a material includes an accumulator comprising an elongated body with an open interior and an inside diameter. A slide tube is slidably mounted within the open interior of the elongated body. The slide tube has a sealing piston head hermetically sealing the open end within the elongated body to define a variable gas containment space. A pressurized gas is supplied to the gas containment space. A rotatable shaping nozzle with an opening for discharging material is provided. A positive displacement extruder delivers material from the accumulator to the nozzle assembly. The nozzle assembly can include a nozzle rotation drive for rotating the shaping nozzle about an axis of rotation. The nozzle opening can be aligned with the axis of rotation, and defines a discharge axis that can be perpendicular to the axis of rotation. A method of additive manufacturing is also disclosed.Type: GrantFiled: September 30, 2020Date of Patent: September 12, 2023Assignee: UT-BATTELLE, LLCInventors: Randall F. Lind, Brian K. Post, Phillip Chesser, Celeste Atkins
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Patent number: 11630439Abstract: Toolpath generation for additive manufacturing systems involves operations on polygonal contours derived from a model for additively manufacturing a structure. One aspect involves modifying or creating a model to allow parts to be printed without starting and stopping the printing equipment by generating continuous toolpaths or toolpaths having a reduced number of isolated paths. Another aspect involves modifying a slicing engine to generate a continuous toolpath or toolpath having a reduced number of isolated paths based on a representation of an object to be additively manufactured. Another aspect involves selectively placing the gaps at alternating positions among the sliced layers to create a zippering effect.Type: GrantFiled: April 7, 2020Date of Patent: April 18, 2023Assignee: UT-Battelle, LLCInventors: Michael C. Borish, Alex C. Roschli, Brian K. Post, Phillip C. Chesser, Seokpum Kim
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Patent number: 11534977Abstract: A system and method for improving additive manufacturing, including additive manufacturing toolpaths, is provided. The system and method includes a toolpath generator that obtains initial toolpaths of an object, identifies isolated paths in the toolpaths, and adds bridge connections between neighboring isolated paths in each layer to improve the toolpaths. The bridge connections facilitate the continuous and non-stop deposition of each layer according to improved toolpaths during additive manufacture, which can reduce total deposition time and improve the resultant additive manufacture.Type: GrantFiled: January 23, 2020Date of Patent: December 27, 2022Assignee: UT-Battelle, LLCInventors: Seokpum Kim, Vlastimil Kune, Ahmed A. Hassen, John M. Lindahl, Brian K. Post, Alex C. Roschli, Phillip C. Chesser, Michael C. Borish, Gregory D. Dreifus, Lonnie J. Love, Craig A. Blue, Bentley T. Beard, II
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Patent number: 11325281Abstract: A method for rapid manufacturing of three dimensional discontinuous fiber preforms is provided. The method includes the deposition of a polymeric material containing fibers on a surface to form a tailored charge for compression molding. The reinforced polymeric material may be a thermoplastic or a reactive polymer with viscosity low enough to allow flow through an orifice during deposition, yet high enough zero shear viscosity to retain the approximate shape of the deposited charge. The material can be deposited in a predetermined pattern to induce the desired mechanical properties through alignment of the fibers. This deposition can be performed in a single layer or in multiple layers. The alignment is achieved passively by shear alignment of the fibers or actively through fiber orientation control or mixing. The fibers can be of the desired material, length, and morphology, including short and long filaments.Type: GrantFiled: July 23, 2019Date of Patent: May 10, 2022Assignee: UT-BATTELLE, LLCInventors: Vlastimil Kunc, Craig A. Blue, Ahmed A. Hassen, John M. Lindahl, Lonnie J. Love, Brian K. Post
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Publication number: 20220097255Abstract: A print head for additive manufacturing with a material includes an accumulator comprising an elongated body with an open interior and an inside diameter. A slide tube is slidably mounted within the open interior of the elongated body. The slide tube has a sealing piston head hermetically sealing the open end within the elongated body to define a variable gas containment space. A pressurized gas is supplied to the gas containment space. A rotatable shaping nozzle with an opening for discharging material is provided. A positive displacement extruder delivers material from the accumulator to the nozzle assembly. The nozzle assembly can include a nozzle rotation drive for rotating the shaping nozzle about an axis of rotation. The nozzle opening can be aligned with the axis of rotation, and defines a discharge axis that can be perpendicular to the axis of rotation. A method of additive manufacturing is also disclosed.Type: ApplicationFiled: September 30, 2020Publication date: March 31, 2022Inventors: Randall F. Lind, Brian K. Post, Phillip Chesser, Celeste Atkins
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Patent number: 11267201Abstract: An assembly for additive manufacturing includes a build housing including a base, a print head, and a print head support connected to the base for supporting the print head above the base. A driver system is provided for moving the print head and the base relative to one another. A build platform comprising a build support and at least one platen. The build support can be detachably engageable to the housing. The platens can be detachably engageable to the build support. The build support can include registration structure for registering the position of the build support relative to the build housing. A method of additive manufacturing is also disclosed.Type: GrantFiled: March 12, 2020Date of Patent: March 8, 2022Assignee: UT-BATTELLE, LLCInventors: Vlastimil Kunc, Ahmed A. Hassen, Brian K. Post, David W. Nuttall, John M. Lindahl, Lonnie J. Love, Tim Deluca, Mike Walch, Benjamin J. Hedger
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Patent number: 11230032Abstract: A cable-driven additive manufacturing system includes an end effector configured for linear translation within a three-dimensional workspace, an aerial hoist suspending the end effector by at least one suspension cable, a plurality of base stations disposed below the aerial hoist, and control cables running from each of the base stations to the end effector.Type: GrantFiled: April 12, 2019Date of Patent: January 25, 2022Assignee: UT-Battelle, LLCInventors: Brian K. Post, Lonnie J. Love, Randall F. Lind, Phillip C. Chesser, Alex C. Roschli
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Publication number: 20210323072Abstract: An electromagnet alignment system for in-situ alignment of a magnetic particulate material is provided. The magnetic particulate material is dispensed through an orifice of a dispensing nozzle used for 3D printing. The system has an electromagnet assembly having a coil. The coil is configured to generate a pulsed magnetic field having a target magnetic flux intensity upon energization of the coil when the magnetic particulate material is being heated and moved through the dispensing nozzle. As a result, the magnetic particulate material is at least partially aligned with respect to a direction by the pulsed magnetic field. The system further includes a power source for implementing the energization of the coil.Type: ApplicationFiled: April 15, 2021Publication date: October 21, 2021Inventors: Mariappan Parans Paranthaman, Brian K. Post, Brian C. Sales
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Patent number: 11111359Abstract: A method of forming a low-density three-dimensional article is provided. The method includes printing a low-density composition on a substrate to form at least one layer comprising the low-density composition. The low-density composition includes a (P) polymer component and (M) a microsphere component in a ratio by volume (P):(M). The method also includes selectively controlling a density of the low-density composition during printing to give the at least one layer on the substrate. Selectively controlling the density of the low-density composition includes varying the ratio (P):(M) during printing. The method further includes repeating the printing and selectively controlling the density of the low-density composition to form additional layer(s), thereby forming the low-density three-dimensional article. A low-density three-dimensional article prepared in accordance with the method is also provided.Type: GrantFiled: May 6, 2019Date of Patent: September 7, 2021Assignee: UT-Battelle, LLCInventors: Vlastimil Kunc, John M. Lindahl, Lonnie J. Love, Brian K. Post, Ahmed Hassen, Peng Liu, Thomas Zeke Sudbury
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Patent number: 11097473Abstract: An additive manufacturing method that includes an extruder providing a supply of working material and a nozzle connected with respect to the extruder, the nozzle directing the working material to a deposit surface. A diverter valve is positioned between the extruder and the nozzle to direct the working material to an exhaust port away from the deposit surface under certain conditions.Type: GrantFiled: August 9, 2018Date of Patent: August 24, 2021Assignee: UT-BATTELLE, LLCInventors: Phillip C. Chesser, Brian K. Post, Matthew R. Sallas, Alex C. Roschli, Randall F. Lind, Lonnie J. Love
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Publication number: 20210055710Abstract: Toolpath generation for additive manufacturing systems involves operations on polygonal contours derived from a model for additively manufacturing a structure. One aspect involves modifying or creating a model to allow parts to be printed without starting and stopping the printing equipment by generating continuous toolpaths or toolpaths having a reduced number of isolated paths. Another aspect involves modifying a slicing engine to generate a continuous toolpath or toolpath having a reduced number of isolated paths based on a representation of an object to be additively manufactured. Another aspect involves selectively placing the gaps at alternating positions among the sliced layers to create a zippering effect.Type: ApplicationFiled: April 7, 2020Publication date: February 25, 2021Inventors: Michael C. Borish, Alex C. Roschli, Brian K. Post, Phillip C. Chesser, Seokpum Kim
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Patent number: 10780612Abstract: A method 100 for generating and dispensing a powdered 60 release agent during an additive manufacturing build is disclosed. A solid body 28 of release agent material is ground insitu by a grinder 50 and dispensed on a surface of the part 72 to prevent adhesion of an adjacent layer of a base material 70. With the addition of the powdered 60 release agent, a support structure 76 is easily separated from the base material 70 when the part 72 is complete, saving time and preventing the part 72 from sustaining unintentional damage. Since no powdered 60 release agent is actually loaded or stored in the apparatus 20, the potential for spillage, waste, inconsistent dispensing, inadvertent dispensing, and clumping due to humidity is eliminated.Type: GrantFiled: August 21, 2018Date of Patent: September 22, 2020Assignee: UT-Battelle, LLCInventors: Randall F. Lind, Brian K. Post, Phillip C. Chesser, Andrew P. Reis, Alex C. Roschli
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Publication number: 20200290276Abstract: An assembly for additive manufacturing includes a build housing including a base, a print head, and a print head support connected to the base for supporting the print head above the base. A driver system is provided for moving the print head and the base relative to one another. A build platform comprising a build support and at least one platen. The build support can be detachably engageable to the housing. The platens can be detachably engageable to the build support. The build support can include registration structure for registering the position of the build support relative to the build housing. A method of additive manufacturing is also disclosed.Type: ApplicationFiled: March 12, 2020Publication date: September 17, 2020Inventors: Vlastimil Kunc, Ahmed A. Hassen, Brian K. Post, David W. Nuttall, John M. Lindahl, Lonnie J. Love, Tim Deluca, Mike Walch, Benjamin J. Hedger
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Patent number: 10766181Abstract: A method for producing magnet-polymer pellets useful as a feedstock in an additive manufacturing process, comprising: (i) blending thermoplastic polymer and hard magnetic particles; (ii) feeding the blended magnet-polymer mixture into a pre-feed hopper that feeds directly into an inlet of a temperature-controlled barrel extruder; (iii) feeding the blended magnet-polymer mixture into the barrel extruder at a fixed feed rate of 5-20 kg/hour, wherein the temperature at the outlet is at least to no more than 10° C. above a glass transition temperature of the blended magnet-polymer mixture; (iv) feeding the blended magnet-polymer mixture directly into an extruding die; (v) passing the blended magnet-polymer mixture through the extruding die at a fixed speed; and (vi) cutting the magnet-polymer mixture at regular intervals as the mixture exits the extruding die at the fixed speed. The use of the pellets as feed material in an additive manufacturing process is also described.Type: GrantFiled: October 27, 2017Date of Patent: September 8, 2020Assignee: UT-Battelle, LLCInventors: Mariappan Parans Paranthaman, Ling Li, Vlastimil Kunc, Brian K. Post, Orlando Rios, Robert H. Fredette, John Ormerod
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Publication number: 20200230888Abstract: A system and method for improving additive manufacturing, including additive manufacturing toolpaths, is provided. The system and method includes a toolpath generator that obtains initial toolpaths of an object, identifies isolated paths in the toolpaths, and adds bridge connections between neighboring isolated paths in each layer to improve the toolpaths. The bridge connections facilitate the continuous and non-stop deposition of each layer according to improved toolpaths during additive manufacture, which can reduce total deposition time and improve the resultant additive manufacture.Type: ApplicationFiled: January 23, 2020Publication date: July 23, 2020Inventors: Seokpum Kim, Vlastimil Kunc, Ahmed A. Hassen, John M. Lindahl, Brian K. Post, Alex C. Roschli, Phillip C. Chesser, Michael C. Borish, Gregory D. Dreifus, Lonnie J. Love, Craig A. Blue, Bentley T. Beard, II
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Publication number: 20200023556Abstract: A method for rapid manufacturing of three dimensional discontinuous fiber preforms is provided. The method includes the deposition of a polymeric material containing fibers on a surface to form a tailored charge for compression molding. The reinforced polymeric material may be a thermoplastic or a reactive polymer with viscosity low enough to allow flow through an orifice during deposition, yet high enough zero shear viscosity to retain the approximate shape of the deposited charge. The material can be deposited in a predetermined pattern to induce the desired mechanical properties through alignment of the fibers. This deposition can be performed in a single layer or in multiple layers. The alignment is achieved passively by shear alignment of the fibers or actively through fiber orientation control or mixing. The fibers can be of the desired material, length, and morphology, including short and long filaments.Type: ApplicationFiled: July 23, 2019Publication date: January 23, 2020Inventors: Vlastimil Kunc, Craig A. Blue, Ahmed A. Hassen, John M. Lindahl, Lonnie J. Love, Brian K. Post
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Publication number: 20190338106Abstract: A method of forming a low-density three-dimensional article is provided. The method includes printing a low-density composition on a substrate to form at least one layer comprising the low-density composition. The low-density composition includes a (P) polymer component and (M) a microsphere component in a ratio by volume (P):(M). The method also includes selectively controlling a density of the low-density composition during printing to give the at least one layer on the substrate. Selectively controlling the density of the low-density composition includes varying the ratio (P):(M) during printing. The method further includes repeating the printing and selectively controlling the density of the low-density composition to form additional layer(s), thereby forming the low-density three-dimensional article. A low-density three-dimensional article prepared in accordance with the method is also provided.Type: ApplicationFiled: May 6, 2019Publication date: November 7, 2019Inventors: Vlastimil Kunc, John M. Lindahl, Lonnie J. Love, Brian K. Post, Ahmed Hassen, Peng Liu, Thomas Zeke Sudbury
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Publication number: 20190315016Abstract: A cable-driven additive manufacturing system includes an end effector configured for linear translation within a three-dimensional workspace, an aerial hoist suspending the end effector by at least one suspension cable, a plurality of base stations disposed below the aerial hoist, and control cables running from each of the base stations to the end effector.Type: ApplicationFiled: April 12, 2019Publication date: October 17, 2019Inventors: Brian K. Post, Lonnie J. Love, Randall F. Lind, Phillip C. Chesser, Alex C. Roschli
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Publication number: 20190047219Abstract: An additive manufacturing method that includes an extruder providing a supply of working material and a nozzle connected with respect to the extruder, the nozzle directing the working material to a deposit surface. A diverter valve is positioned between the extruder and the nozzle to direct the working material to an exhaust port away from the deposit surface under certain conditions.Type: ApplicationFiled: August 9, 2018Publication date: February 14, 2019Applicant: UT-BATTELLE, LLCInventors: Phillip C. CHESSER, Brian K. POST, Matthew R. SALLAS, Alex C. ROSCHLI, Randall F. LIND, Lonnie J. Love