Patents Assigned to Fabric8Labs, Inc.
  • Publication number: 20250122638
    Abstract: An apparatus for use in electrochemical layer deposition includes an anode array containing a plurality of independently electrically controllable anodes and immersible in an electrolyte. The plurality of anodes are arranged in a two-dimensional array. The anode array is connected electrically to, or disposed upon an integrated circuit, semiconductor, or combination of conductive and insulative elements meant for biasing the plurality of anodes with a potential. An anode addressing circuit is provided to receive a signal containing anode address data and to output a signal causing an anode array pattern. The anode addressing circuit communicates with a controller and the anode array. The controller is configured to electrically control each one of the plurality of anodes in the anode array to result in an electrochemical reaction at a cathode to deposit a layer corresponding to the anode array pattern signal received from the addressing circuit.
    Type: Application
    Filed: December 19, 2024
    Publication date: April 17, 2025
    Applicant: Fabric8Labs, Inc.
    Inventors: David Forrest Pain, David Morgan Wirth, Jeffrey William Herman
  • Patent number: 12264405
    Abstract: Described herein are electrochemical additive manufacturing systems and methods of using such systems. In some examples, a method comprises flowing an electrolyte solution into the gap formed by an electrode array and a deposition electrode and depositing (electroplating) a target material onto the deposition electrode. The method also comprises changing one or more characteristics of the electrolyte solution within the system, e.g., to remove deposition byproducts, replenish consumed components, and/or change the solution composition to modify various properties of the deposited target material (e.g., composition, morphology) without major changeovers within the system. These electrolyte changes can be performed dynamically while the system continues to operate. The changed characteristics can be acid concentration, feedstock ion concentration, additive concentration, temperature, and flow rate.
    Type: Grant
    Filed: August 30, 2022
    Date of Patent: April 1, 2025
    Assignee: Fabric8Labs, Inc.
    Inventors: David Pain, Jeffrey Herman, Kareemullah Shaik, Andrew Edmonds
  • Patent number: 12257784
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Grant
    Filed: February 29, 2024
    Date of Patent: March 25, 2025
    Assignee: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman
  • Publication number: 20250043453
    Abstract: An apparatus and method for electrochemically depositing a layer using a reactor configured to contain an electrolyte solution with an anode array containing a plurality of independently electrically controllable anodes arranged in a two-dimensional array, a cathode, at least one sensor and a microcontroller programmed with instructions that when executed by the microcontroller cause the microcontroller to (i) control the current or voltage applied to one anode of the plurality of anodes; (ii) measure the current or the voltage of one anode of the plurality of anodes using the at least one sensor to create a measurement information; (iii) interpret the measurement information causing the microcontroller to send signals to one or more anodes in the anode array to modify their voltage and/or current to cause a localized deposition of the unitary layer structure or the series of unitary layer structures.
    Type: Application
    Filed: July 23, 2024
    Publication date: February 6, 2025
    Applicant: Fabric8Labs, Inc.
    Inventors: David Forrest Pain, David Morgan Wirth, Jeffrey William Herman
  • Publication number: 20250003101
    Abstract: Described herein are printheads for electrochemical-additive manufacturing (ECAM) comprising extended electrode interconnects and other features for preventing electrolyte ingress and protecting the electrode-interface circuits of these printheads. For example, an electrode interconnect may comprise a metal trace extending in-plane between and interconnecting two vertical (out-of-plane) conductors such that the shortest/direct distance between these vertical conductors is substantially smaller than the length/path of this metal trace. As such, the metal trace substantially increases the electrolyte migration path between these vertical conductors. Furthermore, multiple metal traces (at different levels) may be used with vertical conductors being offset from each other. Finally, electrode edges may protrude into the insulator recesses thereby preventing these edges from peeling and increasing the contact interface between the electrodes and the insulator.
    Type: Application
    Filed: February 20, 2024
    Publication date: January 2, 2025
    Applicant: Fabric8Labs, Inc.
    Inventors: Ryan Nicholl, David Pain, Edward White, Lewis Fowler-Gerace
  • Publication number: 20240304440
    Abstract: Described herein are protected electrode arrays and methods of fabricating thereof. Such electrode arrays can be used in electrochemical-additive manufacturing (ECAM) systems and other systems/applications. In some examples, a protected electrode array comprises an electrode-interface circuit and an interposer bonded to the circuit, e.g., using an adhesive layer. The interposer can include an interposer base formed from silicon, glass, and other like materials suitable for operating environments. The interposer base comprises vias, which are aligned with the circuit's electrode connectors, and interposer electrodes deposited within these vias and electrically coupled to the electrode connectors. In some examples, the interposer comprises a base cover and/or electrode covers positioned over the interposer base and the interposer electrodes, respectively.
    Type: Application
    Filed: September 15, 2023
    Publication date: September 12, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: Ryan Nicholl, David Pain, Andrew Edmonds, Kareemullah Shaik, Edward White
  • Patent number: 12049704
    Abstract: An apparatus and method for electrochemically depositing a unitary layer structure using a reactor configured to contain an electrolyte solution with an anode array containing a plurality of independently electrically controllable anodes arranged in a two-dimensional array, a cathode, an addressing circuit configured to receive a signal containing anode address data and configured to output a signal causing an anode array pattern; and, a first controller being a current controller configured to control a flow of current to the anode array; a second controller in communication with the addressing circuit, the current controller and the anode array, the second controller operable to communicate with the current controller to command the flow of current to each anode in the anode array causing an electrochemical reaction at the cathode to deposit a layer corresponding to the anode array pattern signal received from the addressing circuit; and a third controller configured to clear bubbles which have formed on th
    Type: Grant
    Filed: February 23, 2023
    Date of Patent: July 30, 2024
    Assignee: Fabric8Labs, Inc.
    Inventors: David Forrest Pain, David Morgan Wirth, Jeffrey William Herman
  • Publication number: 20240246299
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Application
    Filed: February 29, 2024
    Publication date: July 25, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman
  • Publication number: 20240229273
    Abstract: Described herein are electrochemical-additive manufacturing (ECAM) systems comprising membranes and methods of operating thereof. An ECAM system comprises an electrode array with individually-addressable electrodes, a deposition electrode, and a membrane positioned between the deposition electrode and electrode array. In some examples, the membrane is configured to transmit protons while blocking gas bubbles, such as oxygen bubbles forming at the electrode array surface. Isolating these bubbles from the deposition electrode helps to preserve the desired component resolution of deposited materials. In some examples, the membrane is also configured to block other components (e.g., metal ions) to maintain different electrolyte compositions (e.g., anolyte and catholyte) on the opposite sides of the membrane. For example, the anolyte may comprise multivalent cations that are oxidized (e.g., Fe+2?Fe+3) thereby decreasing the oxygen gas formation.
    Type: Application
    Filed: February 3, 2023
    Publication date: July 11, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: David Pain, Andrew Edmonds, Glenn Sklar, Kareemullah Shaik
  • Publication number: 20240218546
    Abstract: Described herein are electrochemical-additive manufacturing (ECAM) systems comprising electrophoretically-deposited masks selectively covering a set of individually-addressable electrodes (pixels) in the electrode arrays (printheads). For example, an electrophoretically-deposited mask, comprising one or more patches, can be used to block the electric current through certain array portions thereby preventing electrolytic deposition on the corresponding portions of the deposition electrode during ECAM processes. In some examples, electrode array portions can be masked to cover damaged portions (e.g., stuck-on control circuits, electrically and/or ionically conductive passages in the electrode array) and/or to form special patterns of inactive array portions (that no longer need to be controlled using deposition control circuits). Such electrophoretically-deposited masks can be formed in an ECAM system or an external system. The mask forming can be a single-stage process or a multi-stage process.
    Type: Application
    Filed: June 21, 2023
    Publication date: July 4, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: Sean Stone, Kareemullah Shaik, Shiv Shailendar
  • Publication number: 20240218545
    Abstract: Described herein are methods and systems for additive manufacturing of parts comprising electrolytic deposits and electrophoretic deposits. Such methods and methods provide various new ways for integrating different materials into composite parts. Specifically, an additive manufacturing system comprises an electrode array with individually-addressable electrodes. Each individually-addressable electrode is coupled to a separate deposition control circuit, which selectively connects this electrode to a power supply. When forming a composite part, the electrode array can control the location of each electrolytic deposit (by controlling the current flow through each individually-addressable electrode) and each electrophoretic deposit (by controlling the electric field distribution). An electrolyte solution or an electrophoretic suspension is provided between the electrode array and deposition electrode to form corresponding deposits.
    Type: Application
    Filed: June 27, 2023
    Publication date: July 4, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: Michael Matthews, David Pain, Sean Stone, Kareemullah Shaik, Charles Nicholas Pateros, Shiv Shailendar
  • Patent number: 11945170
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Grant
    Filed: June 20, 2023
    Date of Patent: April 2, 2024
    Assignee: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman
  • Publication number: 20230330940
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Application
    Filed: June 20, 2023
    Publication date: October 19, 2023
    Applicant: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman
  • Publication number: 20230304179
    Abstract: An apparatus and method for electrochemically depositing a unitary layer structure using a reactor configured to contain an electrolyte solution with an anode array containing a plurality of independently electrically controllable anodes arranged in a two-dimensional array, a cathode, an addressing circuit configured to receive a signal containing anode address data and configured to output a signal causing an anode array pattern; and a first controller being a current controller configured to control a flow of current to the anode array; a second controller in communication with the addressing circuit, the current controller and the anode array, the second controller operable to communicate with the current controller to command the flow of current to each anode in the anode array causing an electrochemical reaction at the cathode to deposit a layer corresponding to the anode array pattern signal received from the addressing circuit; and a third controller configured to clear bubbles which have formed on the
    Type: Application
    Filed: February 23, 2023
    Publication date: September 28, 2023
    Applicant: Fabric8Labs, Inc.
    Inventors: David Forrest Pain, David Morgan Wirth, Jeffrey William Herman
  • Patent number: 11745432
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Grant
    Filed: December 12, 2022
    Date of Patent: September 5, 2023
    Assignee: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman
  • Publication number: 20230182398
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Application
    Filed: December 12, 2022
    Publication date: June 15, 2023
    Applicant: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman
  • Publication number: 20230089135
    Abstract: Described herein are electrochemical additive manufacturing systems and methods of using such systems. In some examples, a method comprises flowing an electrolyte solution into the gap formed by an electrode array and a deposition electrode and depositing (electroplating) a target material onto the deposition electrode. The method also comprises changing one or more characteristics of the electrolyte solution within the system, e.g., to remove deposition byproducts, replenish consumed components, and/or change the solution composition to modify various properties of the deposited target material (e.g., composition, morphology) without major changeovers within the system. These electrolyte changes can be performed dynamically while the system continues to operate. The changed characteristics can be acid concentration, feedstock ion concentration, additive concentration, temperature, and flow rate.
    Type: Application
    Filed: August 30, 2022
    Publication date: March 23, 2023
    Applicant: Fabric8Labs, Inc.
    Inventors: David Pain, Jeffrey Herman, Kareemullah Shaik, Andrew Edmonds
  • Patent number: 11591705
    Abstract: An apparatus and method for electrochemically depositing a unitary layer structure using a reactor configured to contain an electrolyte solution with an anode array containing a plurality of independently electrically controllable anodes arranged in a two-dimensional array, a cathode, an addressing circuit for receiving a signal containing anode address data and for outputting a signal causing an anode array pattern; and, a controller, in communication with the addressing circuit and the anode array, configured to electrically control each anode in the anode array to cause an electrochemical reaction at the cathode that deposits a unitary layer structure according to the anode array pattern signal.
    Type: Grant
    Filed: April 12, 2021
    Date of Patent: February 28, 2023
    Assignee: Fabric8Labs, Inc.
    Inventors: David Forrest Pain, David Morgan Wirth, Jeffrey William Herman
  • Publication number: 20220081792
    Abstract: An apparatus and method for electrochemically depositing a layer using a reactor configured to contain an electrolyte solution with an anode array containing a plurality of independently electrically controllable anodes arranged in a two-dimensional array, a cathode, an addressing circuit for receiving a signal containing anode address data, and for outputting a signal causing an anode array pattern; in communication with the addressing circuit, the current controller and the anode array, the second controller operable to communicate with the current controller to command the flow of current to each anode in the anode array thereby causing an electrochemical reaction at the cathode to deposit a layer corresponding to the anode array pattern signal received from the addressing circuit.
    Type: Application
    Filed: November 24, 2021
    Publication date: March 17, 2022
    Applicant: Fabric8Labs, Inc.
    Inventors: David Forrest Pain, David Morgan Wirth, Jeffrey William Herman
  • Publication number: 20210301414
    Abstract: An apparatus and method for electrochemically depositing a unitary layer structure using a reactor configured to contain an electrolyte solution with an anode array containing a plurality of independently electrically controllable anodes arranged in a two-dimensional array, a cathode, an addressing circuit for receiving a signal containing anode address data and for outputting a signal causing an anode array pattern; and, a controller. in communication with the addressing circuit and the anode array, configured to electrically control each anode in the anode array to cause an electrochemical reaction at the cathode that deposits a unitary layer structure according to the anode array pattern signal.
    Type: Application
    Filed: April 12, 2021
    Publication date: September 30, 2021
    Applicant: Fabric8Labs, Inc.
    Inventors: David Forrest Pain, David Morgan Wirth, Jeffrey William Herman