Patents by Inventor Kenneth J. Susnjara

Kenneth J. Susnjara 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).

  • 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
  • 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
  • Methods and apparatus for processing and dispensing material during additive manufacturing
    Patent number: 10688719
    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: Grant
    Filed: June 28, 2019
    Date of Patent: June 23, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
  • Systems and methods for printing components using additive manufacturing
    Patent number: 10668664
    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 plurality of sections to manufacture the part.
    Type: Grant
    Filed: November 9, 2018
    Date of Patent: June 2, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal, Nicolas C. Vote
  • Machine and method for forming articles
    Patent number: 10668657
    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: Grant
    Filed: May 3, 2019
    Date of Patent: June 2, 2020
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • SYSTEMS AND METHODS FOR PRINTING COMPONENTS USING ADDITIVE MANUFACTURING
    Publication number: 20200147876
    Abstract: In one embodiment of the present disclosure, 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 plurality of sections to manufacture the part.
    Type: Application
    Filed: November 9, 2018
    Publication date: May 14, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal, Nicolas C. Vote
  • METHODS AND APPARATUS FOR COMPENSATING FOR MATERIAL DISTORTION DURING ADDITIVE MANUFACTURING
    Publication number: 20200139615
    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: November 7, 2019
    Publication date: May 7, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Scott G. Vaal
  • Methods and apparatus for thermal compensation during additive manufacturing
    Patent number: 10632683
    Abstract: A method for thermal compensation during an additive manufacturing process. In some aspects, the method may include receiving, at a CNC machine, information relating to a material used in the additive manufacturing process, wherein the received information includes at least a Coefficient for Thermal Expansion (CTE) for the material. The method may further include modifying a distance of travel for a first pre-programmed tool path based on at least the Coefficient for Thermal Expansion (CTE).
    Type: Grant
    Filed: February 12, 2019
    Date of Patent: April 28, 2020
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • Machine and method for forming articles
    Patent number: 10611073
    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: Grant
    Filed: December 28, 2015
    Date of Patent: April 7, 2020
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • METHODS AND APPARATUS FOR COMPRESSING MATERIAL DURING ADDITIVE MANUFACTURING
    Publication number: 20200061905
    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: September 17, 2019
    Publication date: February 27, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal
  • Methods and apparatus for controlling an applicator head during additive manufacturing
    Patent number: 10549477
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include determining x and y coordinates for a tool path of an additive manufacturing machine, and calculating an angle of the tool path. The method may also include determining a position of a compression roller relative to the angle of the tool path, and moving the compression roller to position the compression roller relative to the angle of the tool path.
    Type: Grant
    Filed: February 17, 2017
    Date of Patent: February 4, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Nicolas Vote
  • Additive manufacturing apparatus
    Patent number: 10532512
    Abstract: An additive manufacturing system may include an extruder. The extruder may include a barrel having a bore. Additionally, the extruder may include an extruder screw at least partially received within the bore of the barrel. The additive manufacturing system also may include a gear pump fluidly coupled to the bore of the barrel. The extruder screw may extend at least partially into the gear pump.
    Type: Grant
    Filed: June 7, 2018
    Date of Patent: January 14, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy
  • METHODS AND APPARATUS FOR COMPENSATING FOR THERMAL EXPANSION DURING ADDITIVE MANUFACTURING
    Publication number: 20200009851
    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: September 17, 2019
    Publication date: January 9, 2020
    Applicant: Thermwood Corporation
    Inventor: Kenneth J. SUSNJARA
  • ADDITIVE MANUFACTURING APPARATUS
    Publication number: 20190375148
    Abstract: An additive manufacturing system may include an extruder. The extruder may include a barrel having a bore. Additionally, the extruder may include an extruder screw at least partially received within the bore of the barrel. The additive manufacturing system also may include a gear pump fluidly coupled to the bore of the barrel. The extruder screw may extend at least partially into the gear pump.
    Type: Application
    Filed: June 7, 2018
    Publication date: December 12, 2019
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy