Patents Assigned to Desktop Metal, Inc.
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Publication number: 20250050413Abstract: 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.Type: ApplicationFiled: March 20, 2024Publication date: February 13, 2025Applicant: Desktop Metal, Inc.Inventors: 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: 12220744Abstract: Devices, systems, and methods are directed to coated powder for three dimensional additive manufacturing. The powder may include a first material coated with a second material, with the coating advantageously resisting segregation of the first material and the second material during handling processes associated with fabrication. The reduced segregation of the first material and the second material may facilitate forming finished three-dimensional parts with improved homogeneity of microstructures and, thus, improved physicochemical properties. More generally, the reduced segregation of the first material and the second material achievable through coating the first material with the second material may facilitate binder jet fabrication using a wider array of combinations of first material and second material as compared to binder jet fabrication using mixtures of constituent powders of the first material and the second material.Type: GrantFiled: June 20, 2019Date of Patent: February 11, 2025Assignee: Desktop Metal, Inc.Inventor: Animesh Bose
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Publication number: 20250001500Abstract: Systems and methods are disclosed for forming a three-dimensional object using additive manufacturing. One method includes depositing a first amount of powder material onto a powder print bed of a printing system, spreading the first amount of powder material across the powder print bed to form a first layer, measuring a density of powder material within the powder print bed, and adjusting a parameter of the printing system based on the measured density of the powder material within the powder print bed.Type: ApplicationFiled: February 5, 2024Publication date: January 2, 2025Applicant: Desktop Metal, Inc.Inventors: George Hudelson, Paul Hoisington, Richard Remo Fontana, Emanuel Sachs, Christopher Anthony Craven, Matthew McCambridge
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Publication number: 20240424572Abstract: Systems and methods for providing inert manufacturing and processing environments. In certain embodiments, a build box having green parts that were manufactured via binder jetting additive manufacturing is sealed with a lid and heat cured in an oven. A supply of process gas is delivered to the build box to provide an inert environment within the build box during the heating process, which results in an exhaust of gaseous species from the build box and prevents contamination from the ambient environment. In certain embodiments, copper-alloy parts are manufactured via binder jetting additive manufacturing in an inert environment to achieve higher final densities after post-processing and sintering.Type: ApplicationFiled: September 13, 2022Publication date: December 26, 2024Applicant: Desktop Metal, Inc.Inventors: George Hudelson, Emanuel M Sachs, Jamison Go, Luke Jorgensen, John Reidy
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Publication number: 20240367235Abstract: The devices, systems, and methods of the present disclosure are directed to spreader positioning techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, an additive manufacturing system may include a roller and a print carriage. In a layer-by-layer fabrication process, the roller may move in advance of the print carriage over a dimension of a volume to spread a respective layer of powder onto which the print carriage delivers a binder. Controlling the position of the roller may facilitate achieving consistent layer characteristics which, in turn, may facilitate fabrication of high quality parts.Type: ApplicationFiled: July 17, 2024Publication date: November 7, 2024Applicant: Desktop Metal, Inc.Inventors: Jonah Samuel Myerberg, Ricardo Fulop, Richard Remo Fontana, Charles Edward Martin, Brett Schuster, Emanuel Michael Sachs
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Patent number: 12121968Abstract: A method for binder jetting a three-dimensional (3D) object includes receiving a geometry of the object to be printed and generating instructions for printing the object. Generating the instructions includes slicing the geometry of the object into a series of cross-sectional shapes corresponding to where a binder fluid will be deposited onto a powder bed to form the object, and including a plurality of negatively printed features within at least some of the series of cross-sectional shapes, wherein an amount of binder fluid to be deposited in the negatively printed features is less than an amount of binder fluid to be deposited in a remainder of the cross-sectional shape. The amount of binder fluid to be deposited in the negatively printed features and a size of the negatively printed features is configured to allow gas to escape from the powder bed.Type: GrantFiled: January 18, 2021Date of Patent: October 22, 2024Assignee: Desktop Metal, Inc.Inventors: Alexander C. Barbati, George Steven Hudelson, Christopher Benjamin Renner, Michael Andrew Gibson
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Patent number: 12077660Abstract: Techniques for debinding additively fabricated parts are described that do not require solvent debinding or catalytic debinding, and that may be performed using only thermal debinding in a furnace. As a result, in at least some cases debinding and sintering may take place sequentially within a single furnace. In some embodiments, the techniques may utilize particular materials as binders that allow for a thermal debinding process that does not negatively affect the parts.Type: GrantFiled: November 13, 2020Date of Patent: September 3, 2024Assignee: Desktop Metal, Inc.Inventors: John Reidy, Christopher Craven, Nihan Tuncer, Animesh Bose, Alexander C. Barbati, Ricardo Fulop, Brian D. Kernan, Karl-Heinz Schofalvi
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Patent number: 12070799Abstract: The devices, systems, and methods of the present disclosure are directed to spreader positioning techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, an additive manufacturing system may include a roller and a print carriage. In a layer-by-layer fabrication process, the roller may move in advance of the print carriage over a dimension of a volume to spread a respective layer of powder onto which the print carriage delivers a binder. Controlling the position of the roller may facilitate achieving consistent layer characteristics which, in turn, may facilitate fabrication of high quality parts.Type: GrantFiled: April 20, 2018Date of Patent: August 27, 2024Assignee: Desktop Metal, Inc.Inventors: Jonah Myerberg, Ricardo Fulop, Richard Fontana, Charles Edward Martin, Brett Schuster, Emanuel Michael Sachs
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Patent number: 12042998Abstract: Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.Type: GrantFiled: February 12, 2023Date of Patent: July 23, 2024Assignee: Desktop Metal, Inc.Inventors: Alexander Barbati, Michael Gibson, George Hudelson, Nicholas Mykulowycz, Brian Kernan, Nihan Tuncer
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Patent number: 12023733Abstract: Methods of additive manufacturing, binder compositions for additive manufacturing, and articles produced by and/or associated with methods of additive manufacturing are generally described.Type: GrantFiled: October 20, 2020Date of Patent: July 2, 2024Assignee: Desktop Metal, Inc.Inventors: Christopher Benjamin Renner, Ilya L. Rushkin, Emanuel M. Sachs
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Patent number: 12017405Abstract: According to some aspects, techniques are provided for fabricating sinterable metallic parts through the application of directed energy to a build material. In particular, applying energy to a build material comprising a polymer mixed with a metal powder may cause the polymer to form a cohesive structure with the metal powder. As a result, the polymer acts as a “glue” to produce a metallic green part without local melting of the metal. The green part may subsequently be sintered to remove the polymer and produce a fully dense metal part. Optionally, a step of debinding may also be performed prior to, or simultaneously with, sintering.Type: GrantFiled: March 30, 2023Date of Patent: June 25, 2024Assignee: Desktop Metal, Inc.Inventors: Jonah Samuel Myerberg, Anastasios John Hart
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Patent number: 12008745Abstract: An additive manufacturing method includes depositing a first amount of metal powder onto a powder bed of a printing system, spreading the first amount of metal powder across the powder bed to form a first layer, and depositing a first amount of binder material on the first layer. The additive manufacturing method also includes exposing the first layer to a first lighting condition, imaging the first layer under the first lighting condition to generate a first image, analyzing the first image of the first layer, and determining whether to adjust at least one printing parameter based on the analyzing.Type: GrantFiled: December 9, 2020Date of Patent: June 11, 2024Assignee: Desktop Metal, Inc.Inventors: George Hudelson, Matthew McCambridge, Jake Dec, Alexander Legendre
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Publication number: 20240181503Abstract: Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts by directing gas onto, or near to, the powder. While fragile green parts, such as green parts produced by binder jetting, may be fragile with respect to scraping or impacts, such parts may nonetheless be resistance to damage from directed gas, even if directed at a high pressure. Techniques for depowdering through directed application of gas may be automated, thereby mitigating challenges associated with manual depowdering operations.Type: ApplicationFiled: February 14, 2024Publication date: June 6, 2024Applicant: Desktop Metal, Inc.Inventors: Jamison Go, Michael Santorella, Jonah Samuel Myerberg, Matthew McCambridge, Alexander LeGendre, Joseph Gabay, Robert J. Nick, Michael Goldblatt
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Publication number: 20240181531Abstract: Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts through vibration of the powder, the parts, and/or structures mechanically connected to the powder and/or parts. For instance, the application of vibration may dislodge, aerate and/or otherwise increase the flowability of regions of the powder, thereby making it easier to remove the powder with a suitable means. Techniques for depowdering through vibration may be automated, thereby mitigating challenges associated with manual depowdering operations.Type: ApplicationFiled: October 24, 2023Publication date: June 6, 2024Applicant: Desktop Metal, Inc.Inventors: Jamison Go, Robert Michael Shydo, JR., Emanuel M. Sachs, Michael Santorella, Midnight Zero, Jonah Samuel Myerberg, Joseph Gabay, Jeffrey von Loesecke, Alexander K. McCalmont
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Patent number: 11998982Abstract: A system and corresponding method for additive manufacturing of a three-dimensional (3D) object to improve packing density of a powder bed used in the manufacturing process. The system and corresponding method enable higher density packing of the powder. Such higher density packing leads to better mechanical interlocking of particles, leading to lower sintering temperatures and reduced deformation of the 3D object during sintering. An embodiment of the system comprises means for adjusting a volume of a powder metered onto a top surface of the powder bed to produce an adjusted metered volume and means for spreading the adjusted metered volume to produce a smooth volume for forming a smooth layer of the powder with controlled packing density across the top surface of the powder bed. The controlled packing density enables uniform shrinkage, without warping, of the 3D object during sintering to produce higher quality 3D printed objects.Type: GrantFiled: February 3, 2021Date of Patent: June 4, 2024Assignee: Desktop Metal, Inc.Inventors: George Hudelson, Emanuel M. Sachs, Glenn A. Jordan, Midnight Zero
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Publication number: 20240165872Abstract: The present invention relates to powder-layer three-dimensional printers (2) having a discrete supply hopper (340) and a recoater (20). The discrete supply hopper (340) is configured to transfer a build powder to the recoater (20) in a manner that enhances the uniformity of build powder layers that are dispensed from the recoater (20). In some embodiments, at least one of the discrete supply hopper and the powder hopper of the recoater is adapted to selectively contact the other, seal against the other, and/or have one partially inserted inside the other so as to diminish or prevent powder pluming during the transfer of build powder from the discrete supply hopper to the recoater.Type: ApplicationFiled: June 14, 2023Publication date: May 23, 2024Applicant: Desktop Metal, Inc.Inventors: Jake Flick, Michael John McCoy, Joseph J. Bolt, Alec Hydock, Travis Maxwell Inks, Anthony S. Dugan, Thomas Lizzi
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Patent number: 11980940Abstract: A controlled environment system for the additive manufacture of metal objects using magnetohydrodynamic jetting. A sealing plate is placed against an Péclet gap seal of a volume enclosure. A flow of inert gas is used to maintain a high-purity volume in the interior of the volume enclosure. A print head accesses the interior and delivers build material through a hole in the sealing plate. A build plate is movable relative to the sealing plate within the interior of the volume enclosure on which objects can be fabricated.Type: GrantFiled: March 20, 2020Date of Patent: May 14, 2024Assignee: Desktop Metal, Inc.Inventors: Emanuel Michael Sachs, Julian Bell, Nicholas Graham Bandiera
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Publication number: 20240139806Abstract: Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from additively fabricated parts through liquid immersion of the parts. Motion of the liquid, such as liquid currents, may dislodge or otherwise move powder away from additively fabricated parts to which it is adhered or otherwise proximate to. The liquid may also provide a vehicle to carry away powder from the additively fabricated parts. Removed powder may be filtered or otherwise separated from the liquid to allow recirculation of the liquid to the parts and/or to enable re-use of the powder in subsequent additive fabrication processes. Techniques for depowdering through liquid immersion may be automated, thereby mitigating challenges associated with manual depowdering operations.Type: ApplicationFiled: August 1, 2023Publication date: May 2, 2024Applicant: Desktop Metal, Inc.Inventors: Jamison Go, Daniel Sachs, Robert J. Nick, Jonah Samuel Myerberg, Michael Goldblatt
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Patent number: 11969795Abstract: 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.Type: GrantFiled: March 24, 2017Date of Patent: April 30, 2024Assignee: Desktop Metal, Inc.Inventors: 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: 11951515Abstract: Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts by directing gas onto, or near to, the powder. While fragile green parts, such as green parts produced by binder jetting, may be fragile with respect to scraping or impacts, such parts may nonetheless be resistance to damage from directed gas, even if directed at a high pressure. Techniques for depowdering through directed application of gas may be automated, thereby mitigating challenges associated with manual depowdering operations.Type: GrantFiled: August 3, 2020Date of Patent: April 9, 2024Assignee: Desktop Metal, Inc.Inventors: Jamison Go, Michael Santorella, Jonah Samuel Myerberg, Matthew McCambridge, Alexander LeGendre, Joseph Gabay, Robert J. Nick, Michael Goldblatt