Patents by Inventor Richard Remo Fontana
Richard Remo Fontana 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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Publication number: 20190329500Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.Type: ApplicationFiled: July 11, 2019Publication date: October 31, 2019Applicant: Desktop Metal, Inc.Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
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Publication number: 20190329502Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.Type: ApplicationFiled: July 11, 2019Publication date: October 31, 2019Applicant: Desktop Metal, Inc.Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
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Publication number: 20190329501Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.Type: ApplicationFiled: July 11, 2019Publication date: October 31, 2019Applicant: Desktop Metal, Inc.Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
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Patent number: 10456833Abstract: A variety of additive manufacturing techniques can be adapted to fabricate a substantially net shape object from a computerized model using materials that can be debound and sintered into a fully dense metallic part or the like. However, during sintering, the net shape will shrink as binder escapes and the base material fuses into a dense final part. If the foundation beneath the object does not shrink in a corresponding fashion, the resulting stresses throughout the object can lead to fracturing, warping or other physical damage to the object resulting in a failed fabrication. To address this issue, a variety of techniques are disclosed for substrates and build plates that contract in a manner complementary to the object during debinding and sintering.Type: GrantFiled: January 11, 2018Date of Patent: October 29, 2019Assignee: Desktop Metals, Inc.Inventors: Michael Andrew Gibson, Jonah Samuel Myerberg, Ricardo Fulop, Ricardo Chin, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Publication number: 20190322046Abstract: A system and corresponding method to move build material in a three-dimensional (3D) printing system uses a gripper. The gripper is arranged to apply at least two opposing lateral forces to the build material. The at least two opposing lateral forces are applied to the build material, in conjunction with linear motion of the gripper, for at least a portion of a path the build material travels toward an extrusion head.Type: ApplicationFiled: July 2, 2019Publication date: October 24, 2019Applicant: Desktop Metal, Inc.Inventors: Richard Burnham, John LaPlante, Aaron Preston, Richard Remo Fontana
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Patent number: 10384396Abstract: A system and corresponding method to move build material in a three-dimensional (3D) printing system uses a gripper. The gripper is arranged to apply at least two opposing lateral forces to the build material. The at least two opposing lateral forces are applied to the build material, in conjunction with linear motion of the gripper, for at least a portion of a path the build material travels toward an extrusion head.Type: GrantFiled: April 24, 2018Date of Patent: August 20, 2019Assignee: Desktop Metal, Inc.Inventors: Richard Burnham, John LaPlante, Aaron Preston, Richard Remo Fontana
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Publication number: 20190240730Abstract: A three-dimensional printer includes a vessel containing a liquid in which a printed object can debind during fabrication. More generally, the vessel may contain any liquid medium selected to control or modify properties of a printed object during fabrication. For example, the liquid may also or instead impose a controlled thermal environment for the printed object, apply finishing materials to an exterior surface of the object, provide a component or catalyst for a reaction, or otherwise treat the printed object or control ambient conditions during printing.Type: ApplicationFiled: February 2, 2018Publication date: August 8, 2019Inventors: Charles John Haider, Michael Andrew Gibson, Richard Remo Fontana, Alexander C. Barbati
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Patent number: 10350682Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is fabricated between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. Interface layers suitable for manufacture with an additive manufacturing system may resist the formation of bonds between a support structure and an object during subsequent sintering processes.Type: GrantFiled: March 24, 2017Date of Patent: July 16, 2019Assignee: Desktop Metal, Inc.Inventors: Jonah Samuel Myerberg, Michael Andrew Gibson, Ricardo Fulop, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Publication number: 20190160529Abstract: A materials processing furnace provides for debinding and sintering objects and treating effluent generated by the sintering. A heating chamber maintains a controlled atmosphere for sintering the object. A vacuum pump evacuates an effluent from the heating chamber, and an injector adds a reagent to the evacuated effluent to form a mixed gas. A catalytic converter receives the mixed gas and catalyzes one or more hazardous or offensive compounds of the effluent, thereby converting the effluent to a safer and less offensive exhaust. As a result, the furnace is suitable for operation in an office environment.Type: ApplicationFiled: November 29, 2018Publication date: May 30, 2019Inventors: Aaron Silidker, Richard Remo Fontana, Brian Kernan, Mark Sowerbutts, Tomek Brzezinski, Ricardo Fulop, Leon Fay, Daniel R. Jepeal
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Patent number: 10272492Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. The support structure may be a multi-part support structure to mitigate mold lock or facilitate removal from enclosed spaces.Type: GrantFiled: March 24, 2017Date of Patent: April 30, 2019Assignee: Desktop Metal, Inc.Inventors: Michael Andrew Gibson, Jonah Samuel Myerberg, Ricardo Fulop, Ricardo Chin, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Publication number: 20190118260Abstract: Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.Type: ApplicationFiled: October 25, 2018Publication date: April 25, 2019Inventors: Peter Alfons Schmitt, Jonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Patent number: 10232443Abstract: A printer fabricates an object from a computerized model using a fused filament fabrication process. The shape of an extrusion nozzle may be varied during extrusion to control, e.g., an amount of build material deposited, a shape of extrudate exiting the nozzle, a feature resolution, and the like.Type: GrantFiled: June 29, 2018Date of Patent: March 19, 2019Assignee: DESKTOP METAL, INC.Inventors: Jonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Anastasios John Hart, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Matthew David Verminski, Emanuel Michael Sachs, Ricardo Chin
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Publication number: 20190060997Abstract: Additive fabrication systems generally use support structures to expand the available range of features and geometries in fabricated objects. For example, when a vertical shelf or cantilever extends from an object, a supplemental support structure may be required to provide a surface for fabrication thereon. This process may become more difficult when, e.g., a part will be subjected to downstream processing steps such as debinding or sintering that impose different design rules. To address these challenges and provide a greater range of flexibility and processing speed, it may be useful in certain circumstances to independently fabricate the object and support structures, and then assemble these structures into a composite item for debinding and sintering. This approach also advantageously facilitates various techniques for spraying, dipping, or otherwise applying a release layer between the support structure and the part so that these separate items do not become fused together during sintering.Type: ApplicationFiled: October 25, 2018Publication date: February 28, 2019Inventors: Michael Andrew Gibson, Jonah Samuel Myerberg, Ricardo Fulop, Ricardo Chin, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Patent number: 10201854Abstract: Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. The magnetohydrodynamic force can be pulsed to eject droplets of the liquid metal to provide control over accuracy of the object being fabricated. The pulsations can be applied in fluid chambers having high resonance frequencies such that droplet ejection can be effectively controlled over a wide range of frequencies, including high frequencies suitable for liquid metal ejection at rates suitable for commercially viable three-dimensional fabrication.Type: GrantFiled: March 6, 2017Date of Patent: February 12, 2019Assignee: Desktop Metal, Inc.Inventors: Emanuel Michael Sachs, Mark Gardner Gibson, Paul A. Hoisington, Richard Remo Fontana
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Patent number: 10195665Abstract: Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. Nozzles associated with these devices, systems, and methods include a combination of materials suitable for withstanding prolonged exposure to high temperatures associated with certain liquid metals while facilitating efficient delivery of current to produce magnetohydrodynamic forces controllable over a range of frequencies associated with commercially viable three-dimensional fabrication.Type: GrantFiled: March 6, 2017Date of Patent: February 5, 2019Assignee: Desktop Metal, Inc.Inventors: Emanuel Michael Sachs, Richard Remo Fontana
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Patent number: 10189204Abstract: Techniques and compositions are disclosed for composite feedstocks with powder/binder systems suitable for three-dimensional printing, such as fused filament fabrication. The composite feedstocks may include a jacket about a core, with at least the core including a powder material suspended in a binder system and the jacket having a hardness or toughness greater than a hardness or toughness of the core for the feedstock. In general, the harder jacket may protect the core from unintended deformation or damage during transportation, storage, or use. For example, the difference in hardness or toughness between the jacket and the core may facilitate gripping the feedstock (e.g., by gear drives or the like) with a higher amount of force than is otherwise applicable if the feedstock were composed of the core alone, without damaging the core, during a fused filament fabrication process or another additive manufacturing process.Type: GrantFiled: December 14, 2017Date of Patent: January 29, 2019Assignee: Desktop Metal, Inc.Inventors: Ricardo Fulop, Michael Andrew Gibson, Richard Remo Fontana, Animesh Bose, Jonah Samuel Myerberg
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Publication number: 20190001412Abstract: A variety of additive manufacturing techniques can be adapted to fabricate a substantially net shape object from a computerized model using materials that can be debound and sintered into a fully dense metallic part or the like. However, during sintering, the net shape will shrink as binder escapes and the base material fuses into a dense final part. If the foundation beneath the object does not shrink in a corresponding fashion, the resulting stresses throughout the object can lead to fracturing, warping, or other physical damage to the object resulting in a failed fabrication. To address this issue, a variety of techniques are disclosed for substrates and build plates that contract in a manner complementary to the object during debinding and sintering.Type: ApplicationFiled: September 5, 2018Publication date: January 3, 2019Inventors: Michael Andrew Gibson, Jonah Samuel Myerberg, Ricardo Fulop, Ricardo Chin, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Publication number: 20180318933Abstract: A printer fabricates an object from a computerized model using a fused filament fabrication process. A former extending from a nozzle of the printer supplements a layer fusion process by applying a normal force on new material as it is deposited to form the object. The former may use a variety of techniques such as heat and rolling to improve physical bonding between layers.Type: ApplicationFiled: June 29, 2018Publication date: November 8, 2018Inventors: Jonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Anastasios John Hart, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Matthew David Verminski, Peter Alfons Schmitt, Emanuel Michael Sachs, Ricardo Chin
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Publication number: 20180318925Abstract: A support structure is fabricated below a printed object to form a structure that prevents or minimizes a drag on a floor while the object shrinks during sintering.Type: ApplicationFiled: June 28, 2018Publication date: November 8, 2018Inventors: Jonah Samuel Myerberg, Michael Andrew Gibson, Ricardo Fulop, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Publication number: 20180318932Abstract: A printer fabricates an object from a computerized model using a fused filament fabrication process. The shape of an extrusion nozzle may be varied during extrusion to control, e.g., an amount of build material deposited, a shape of extrudate exiting the nozzle, a feature resolution, and the like.Type: ApplicationFiled: June 29, 2018Publication date: November 8, 2018Inventors: Jonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Anastasios John Hart, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Matthew David Verminski, Peter Alfons Schmitt, Emanuel Michael Sachs, Ricardo Chin