Patents Represented by Attorney James E. Curry
  • Patent number: 7789544
    Abstract: A modular light rack assembly for off-road vehicles having a plurality of individual pieces that can be selectively connected to form a substantially linear assembly for attaching a variety of headlight subassemblies. In each embodiment, there is a common left hand mounting configuration and common right hand mounting configuration, so that each piece of the modular light rack assembly having one or both of these configurations on its end or ends is selectively connectable to any other piece to form a substantially linear assembly of any desired configuration.
    Type: Grant
    Filed: October 10, 2007
    Date of Patent: September 7, 2010
    Assignee: Baja Designs, Inc.
    Inventors: Alan R. Roach, Stephen J. Mitchell
  • Patent number: 7249875
    Abstract: A light rack assembly for off-road vehicles capable of surviving high vibration loads generated in off-road racing. Each assembly comprises at least one headlight sub-assembly having a center of gravity that, when mounted to the frame of the light rack assembly, resides in a spherical zone defined by the effective radius of the light and the mounting points of the light housing. Each light is isolated from vibration of the vehicle and can be individually adjusted to the preference of the driver without tools. The light rack assembly can be quickly removed from the vehicle, or be mounted such that the assembly can be rotated to adjust the light beams while the vehicle is in motion and rotated to retract the assembly to protect the lights when not in use.
    Type: Grant
    Filed: April 15, 2005
    Date of Patent: July 31, 2007
    Assignee: Baja Designs, Inc.
    Inventors: Alan R. Roach, Stephen J. Mitchell
  • Patent number: 7033160
    Abstract: A convection cooling technique for selective deposition modeling utilizing a venturi duct to establish a low-pressure port for drawing a second flow of air into the duct. The second flow of air is drawn across a heat generating component in the selective deposition modeling apparatus. A low-pressure zone is established at the low-pressure port sufficient to meet the head loss that results when drawing the second flow across the heat generating component and into the venturi duct. A desired flow rate is achieved at a pressure drop that is greater than that possible by the direct use of a fan. The cooling system is well suited for use in providing steady state cooling of radiation exposure systems used in selective deposition modeling to initiate curing of the layers of dispensed material.
    Type: Grant
    Filed: May 28, 2002
    Date of Patent: April 25, 2006
    Assignee: 3D Systems, Inc.
    Inventor: Jon Jody Fong
  • Patent number: 7011783
    Abstract: A cooling system for removing heat from the layers of a three-dimensional object built in a layerwise manner from a build material in a solid freeform fabrication apparatus. The cooling system provides an air duct that delivers a uniform sheet of air flow over the layers of the three-dimensional object while it is built. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).
    Type: Grant
    Filed: December 5, 2001
    Date of Patent: March 14, 2006
    Assignee: 3D Systems, Inc.
    Inventor: Jon Jody Fong
  • Patent number: 7008206
    Abstract: A ventilation and cooling system for a selective deposition modeling apparatus dispensing a curable material. The ventilation and cooling system captures airborne contaminants in the apparatus making the apparatus suitable for use in an office environment. A pressure drop is established within the apparatus to assure that all air that enters the apparatus passes through a filter which captures the airborne contaminants before the air is expelled from the apparatus. Sensors are provided to assure that the ventilation and cooling system is function properly, and if not, the apparatus is either shut down or a signal is provided to the operator indicating that the system is not functioning properly.
    Type: Grant
    Filed: June 24, 2002
    Date of Patent: March 7, 2006
    Assignee: 3D Systems, Inc.
    Inventors: Jon Jody Fong, Raymond M. Soliz, Gary Lee Reynolds
  • Patent number: 6936212
    Abstract: A method of forming a three-dimensional object in a layerwise manner is disclosed. The object is formed in a manner-that substantially prevents non-uniform distortion to occur during the layerwise build process as the build material forming the object solidifies and shrinks. The formed object comprises an outer surface defined by a shell structure and an internal lattice structure residing within the internal volume of the object. The object may be formed by any selective deposition modeling apparatus from a wide variety of materials.
    Type: Grant
    Filed: February 7, 2002
    Date of Patent: August 30, 2005
    Assignee: 3D Systems, Inc.
    Inventor: Clark W. Crawford
  • Patent number: 6916441
    Abstract: A method for removing supports from a three-dimensional object formed by solid freeform fabrication. The three-dimensional object and support structure both contain a phase change component in order to achieve the desired phase change characteristics needed for dispensing the material. The method prevents the phase change material within the three-dimensional object from migrating within the object during post processing to remove the support structure.
    Type: Grant
    Filed: February 25, 2002
    Date of Patent: July 12, 2005
    Assignee: 3D Systems, Inc.
    Inventors: Kenneth J. Newell, Kris Alan Schmidt, Michael Thomas Sherwood
  • Patent number: 6841116
    Abstract: A selective deposition modeling method and apparatus for dispensing a curable phase change material. The dispensing temperature of the material is set at or less than a thermally stable temperature value for the material in which the reactive component of the material remains substantially uncured when held at the temperature for a desired time period. The dispensed material is provided with an environment that enables the material to solidify to form layers of the object. The solidified material is normalized to a desired layer thickness and is then cured by exposure to actinic radiation. In a preferred embodiment a UV curable phase change material is dispensed at about 80° C. and has a viscosity of about 13 to about 14 centipoise at this temperature. The cured material provides substantially increased physical properties over thermoplastic phase change materials previously used in selective deposition modeling.
    Type: Grant
    Filed: October 3, 2001
    Date of Patent: January 11, 2005
    Assignee: 3D Systems, Inc.
    Inventor: Kris Alan Schmidt
  • Patent number: 6813594
    Abstract: A solid freeform fabrication method and apparatus for making objects in a layer by layer manner in which the objects have special geometrical features requiring specialized control parameters. The method and apparatus automatically determines and selects the build parameters for the build process based on automatic part feature recognition. A general build style is first determined having a plurality of default parameters for building the object. Data representing the object is imported and oriented with a Z-axis. The data is then processed by slicing software that automatically identifies special build types for specific ranges of Z-values and selects the alternative parameters needed to successfully build these features. Preferably a look-up table contains special sets of values for the parameters for each special build type possible in which the slicing algorithm can select from. During slicing, operator intervention is not needed to prepare all the parameters necessary for a successful build.
    Type: Grant
    Filed: May 3, 2001
    Date of Patent: November 2, 2004
    Assignee: 3D Systems, Inc.
    Inventors: Michelle D. Guertin, Chris R. Manners
  • Patent number: 6782303
    Abstract: A selective deposition modeling apparatus utilizing a planarizer to dimensionally normalize the layers of a three-dimensional object as it is being built. The apparatus includes a means for measuring the power used to dimensionally normalize the layers which is indicative of the amount of excess build material that has been dispensed. The apparatus then utilizes the measurement to alter the excess amount of build material of a next dispensed layer so as to optimize the build rate and reduce the production of waste material. In one embodiment the planarizer is rotated at a constant angular velocity by a motor and the current supplied to the motor is monitored, and a print head supplied with a firing voltage is used to dispense the build material. The voltage supplied to the print head is adjusted to optimize the build rate of the apparatus.
    Type: Grant
    Filed: November 30, 2001
    Date of Patent: August 24, 2004
    Assignee: 3D Systems, Inc.
    Inventor: Jon Jody Fong
  • Patent number: 6752948
    Abstract: A method for removing supports from a three-dimensional objected formed by selective deposition modeling. The three-dimensional object is formed from a curable phase change material and the supports are formed from a non-curable phase change material. The curable phase change material contains between about 5% to about 25% of a non-reactive wax in order to achieve the desired phase change characteristics of the material. When removing the supports with heat, discoloration undesirably occurs in the three-dimensional object as the non-reactive wax migrates within the object. The method prevents wax migration by cooling the object slowly past the freezing point of the build material such that a temperature differential no greater than about 5° C. is present within the object. With the preferred build material having a freezing point of about 49.5° C., this is achieved by lowering the temperature between about 62° C. to about 52° C.
    Type: Grant
    Filed: October 3, 2001
    Date of Patent: June 22, 2004
    Assignee: 3D Systems, Inc.
    Inventors: Kenneth J. Newell, Stephen A. Ruatta, John S. Stockwell
  • Patent number: 6713125
    Abstract: A method for processing a three-dimensional object formed by solid freeform fabrication from a build material having a polymer component to alter the appearance of the object. A fluid medium carrying an infiltration agent is applied to the object at a temperature above the glass transition temperature of the polymer component for a desired period of time wherein the infiltration agent penetrates the three-dimensional object. The infiltration agent can be a dye that can alter the color of the object.
    Type: Grant
    Filed: March 13, 2002
    Date of Patent: March 30, 2004
    Assignee: 3D Systems, Inc.
    Inventors: Michael Thomas Sherwood, Pingyong Xu
  • Patent number: 6711451
    Abstract: A power management system for a selective deposition modeling apparatus for maintaining the power consumption of the apparatus within the limits of conventional power available in most all office environments. The apparatus has a plurality of power drawing components, each component having a activation power rating wherein the accumulative total of all the power ratings exceeds a baseline power consumption value for the apparatus. The system prevents a baseline power consumption value from being exceeded by determining which components can be activated while leaving others inactivated.
    Type: Grant
    Filed: July 2, 2002
    Date of Patent: March 23, 2004
    Assignee: 3D Systems, Inc.
    Inventors: Mark Hastert, Arvind Chari
  • Patent number: 6660208
    Abstract: A detoxification process for rendering three-dimensional objects formed by solid freeform fabrication techniques biocompatible for use in long-term dermal contact applications. The process nullifies cytotoxins normally present in objects formed by solid freeform fabrication techniques rendering such techniques as viable for the production of biocompatible devices such as stents, artery valve components, bone implant supports, pacemaker shells, surgical tools, and the like. In one embodiment, a custom hearing aid shell is produced by stereolithography from an acrylate photopolymer resin that was detoxified for long-term dermal contact application. The detoxification process makes three-dimensional objects created by solid freeform fabrication techniques available for products requiring biocompatibility.
    Type: Grant
    Filed: March 30, 2001
    Date of Patent: December 9, 2003
    Assignee: 3D Systems, Inc.
    Inventor: Stephen D. Hanna
  • Patent number: 6656410
    Abstract: A method of applying highly viscous paste-like build materials in layers in a solid freeform fabrication apparatus to form three-dimensional objects. A viscosity modifier is first introduced into the build material to establish a low viscosity state and then the material is dispensed in layers on a working surface. The viscosity modifier is then removed from the build material preferably by evaporation, and the layer is selectively solidified to form the three-dimensional object. The method substantially eliminates the undesirable effects of induced shear stress imposed on lower layers when attempting to apply uniform layers of highly viscous materials in solid freeform fabrication techniques. The method allows for the use of highly viscous paste-like materials that can include upwards of 50% by weight of metallic, ceramic, mineral, or polymer powders. Preferably the binder is a photocurable resin or thermocurable material which is selectively solidified to form the three-dimensional objects.
    Type: Grant
    Filed: January 17, 2002
    Date of Patent: December 2, 2003
    Assignee: 3D Systems, Inc.
    Inventors: Charles W. Hull, Kenneth J. Newell
  • Patent number: 6646728
    Abstract: The invention relates in general to calibrating a focused beam of energy in a solid freeform fabrication apparatus, and, in particular, to a method of measuring the propagation characteristics of the beam to produce beam propagation data. The beam propagation data can be used to verify that the beam is operating within tolerance, and/or produce a response that can be used to further calibrate the beam. The invention is particularly useful in determining asymmetric conditions in the beam. The beam propagation data is produced in accord with the “M2” standard for characterizing a beam. In one embodiment, the response indicates the beam is unacceptable for use in the apparatus. In another embodiment, the response is provided to calibrate the focal position of the beam. In still another embodiment, the response is provided to an adjustable beam that eliminates the asymmetric condition.
    Type: Grant
    Filed: July 9, 2001
    Date of Patent: November 11, 2003
    Assignee: 3D Systems, Inc.
    Inventors: Nansheng Tang, Jouni P. Partanen
  • Patent number: 6572807
    Abstract: An improved selective deposition modeling method which produces a cold weld joint in an object formed by dispensing a single phase change material. The cold weld joint can be controlled so that a lower portion of the object can serve as a support structure for forming the upper portion of the object. Upon separation of the lower and upper portions along the cold weld joint, a downward facing surface is revealed on the upper portion exhibiting superior detail and quality compared to other downward facing surfaces created by conventional selective deposition modeling techniques. The method can readily be adapted for use by selective deposition modeling machines utilizing ink jet print heads dispensing a single phase change material.
    Type: Grant
    Filed: October 26, 2000
    Date of Patent: June 3, 2003
    Assignee: 3D Systems, Inc.
    Inventor: Jon Jody Fong
  • Patent number: 6562269
    Abstract: An improved layer normalizing device for use in dimensionally normalizing layers of a three-dimensional model produced by a selective deposition modeling technique. The layer normalizing device employs a wicking member having a body and a normalizing surface for dimensionally normalizing the object while the object is being built layer by layer. The body includes a plurality of interstices, and when the wicking member is sufficiently heated to cause the build material to become flowable, excess material is drawn by capillary action from the layer of the object being normalized and into the wicking member. A refreshing means is provided to remove the excess build material from the interstices of the wicking member and allow the wicking member to draw additional build material by capillary action.
    Type: Grant
    Filed: January 5, 2001
    Date of Patent: May 13, 2003
    Assignee: 3D Systems, Inc.
    Inventor: Jon Jody Fong
  • Patent number: 6492651
    Abstract: A closed loop selective deposition modeling apparatus having a surface scanning system for actively monitoring the surface height of a layer of a three-dimensional object as it is being built by selectively dispensing a build material. The surface scanning system directs a beam of energy on the surface of the object that establishes an illumination zone which emits scattered light, and has a detector which senses the scattered light and produces a response indicative of the surface condition of the object. The response is processed to establish a plurality of height data signals that are further processed to produce feedback data. The feedback data is then utilized to selectively dispense the build material to desired locations on the surface of the object to therein dimensionally normalize the layer of the object being formed.
    Type: Grant
    Filed: February 8, 2001
    Date of Patent: December 10, 2002
    Assignee: 3D Systems, Inc.
    Inventor: Thomas A. Kerekes
  • Patent number: D564683
    Type: Grant
    Filed: March 7, 2006
    Date of Patent: March 18, 2008
    Assignee: Baja Designs, Inc.
    Inventors: Alan R. Roach, Stephen J. Mitchell