Patents Assigned to PostProcess Technologies, Inc.
  • Publication number: 20230141106
    Abstract: A surface equalization apparatus designed to be compatible with a wide variety of part technologies, composite materials and part geometries. The apparatus works with software, chemistry, abrasives and media and includes an oblong, elongated input tank for holding media and a part. The input tank is connected to a motor mount, which is connected to an eccentric motor. When the motor is activated, the input tank begins to move in a vibrational, sinusoidal manner. The motion of the tank on attached springs generates a rotational flow of media in the tank. This creates a low amplitude/high frequency movement of the part through the tank. Surface structures divert media to prevent the part from contacting the side of the tank. Spray nozzles are positioned above the input tank. Acoustic damping foam is positioned around the central components. A cooling fan allows airflow through the apparatus.
    Type: Application
    Filed: December 30, 2022
    Publication date: May 11, 2023
    Applicant: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Publication number: 20230099420
    Abstract: A system and method are disclosed for additively manufacturing an object having an internal chase. The system and method include evaluating a print design file that defines physical properties of the object to be printed with the additive manufacturing process to determine whether the object can be printed with a removable plug located inside the internal chase, and if so, modifying the print design file to include the removable plug. The object is then printed with the removable plug, which is removed prior to removing the support material.
    Type: Application
    Filed: February 5, 2021
    Publication date: March 30, 2023
    Applicant: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Patent number: 11565466
    Abstract: A surface equalization apparatus designed to be compatible with a wide variety of part technologies, composite materials and part geometries. The apparatus works with software, chemistry, abrasives and media and includes an oblong, elongated input tank for holding media and a part. The input tank is connected to a motor mount, which is connected to an eccentric motor. When the motor is activated, the input tank begins to move in a vibrational, sinusoidal manner. The motion of the tank on attached springs generates a rotational flow of media in the tank. This creates a low amplitude/high frequency movement of the part through the tank. Surface structures divert media to prevent the part from contacting the side of the tank. Spray nozzles are positioned above the input tank. Acoustic damping foam is positioned around the central components. A cooling fan allows airflow through the apparatus.
    Type: Grant
    Filed: June 30, 2017
    Date of Patent: January 31, 2023
    Assignee: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Patent number: 11524464
    Abstract: An apparatus and method for removing support material from and/or smoothing surfaces of an additively manufactured part (the “AM part”) is disclosed. The apparatus may include a chamber, a support surface within the chamber, and one or more nozzles within the chamber. The nozzles may be the same size or different sizes. The support surface may be configured to support the AM part. The support surface may have one or more openings sized and configured to allow the fluid to pass through the opening(s). The nozzles may be configured to spray a fluid at the AM part, and the spray may be an atomized or semi-atomized spray of the fluid. For removing support material from parts with internal spaces, such as cavities or passages, the apparatus can include a nozzle at the end of an adjustable flexible hose member that can be adjusted to spray into an internal space of the part. Alternatively, for removing unwanted support material from multiple parts with internal spaces, the apparatus may include a submersion tank.
    Type: Grant
    Filed: September 30, 2020
    Date of Patent: December 13, 2022
    Assignee: PostProcess Technologies, Inc.
    Inventors: Nicholas Cudzilo, Jon Strible, Daniel J. Hutchinson, Marc Farfaglia
  • Publication number: 20220363002
    Abstract: An apparatus and method for removing support material from and/or smoothing surfaces of an additively manufactured part is disclosed. The apparatus may include a chamber, a support surface within the chamber, one or more nozzles within the chamber, a tank positioned below the nozzles, and a vision system. The vision system includes one or more cameras and other imagery obtaining sensors located in the chamber. The cameras and sensors obtain imagery of the additively manufactured part as it is being sprayed to finish the part. The imagery is displayed on a display panel located outside the apparatus or stored for later playback.
    Type: Application
    Filed: July 27, 2022
    Publication date: November 17, 2022
    Applicant: PostProcess Technologies, Inc.
    Inventors: Daniel Joshua Hutchinson, Owen Wegman, Gary Burch, Marc Farfaglia
  • Patent number: 11491724
    Abstract: Apparatuses and methods for removing support material from and/or smoothing surfaces of an additive-manufactured part are disclosed. Apparatuses may include a spraying chamber, a support surface within the spraying chamber, and one or more nozzles having the ability to spray a fluid at the additive-manufactured parts. The fluid may include a liquid and solid particles carried by the liquid. The support surface may have the ability to support the additive manufactured part. The apparatus may include a tank having the ability to hold at least some of the fluid. A heater may be included for heating the fluid to a desired temperature.
    Type: Grant
    Filed: December 4, 2018
    Date of Patent: November 8, 2022
    Assignee: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Publication number: 20220340779
    Abstract: Described are finishing mediums for removing support material and/or for surface finishing of objects made via additive manufacturing techniques. The finishing medium is an aqueous solution containing 1-20% by weight a polyol, 1-20% by weight an anti-corrosion agent, 0.001-10% by weight a hydrotrope. The finishing medium may optionally suspend media particles, thereby forming a finishing suspension. Also described are methods of using the finishing media and finishing suspensions described herein.
    Type: Application
    Filed: July 1, 2022
    Publication date: October 27, 2022
    Applicant: PostProcess Technologies, Inc.
    Inventors: Daniel Joshua Hutchinson, Marc Farfaglia, Cassidy Grant
  • Publication number: 20220281172
    Abstract: Systems and methods according to the invention are used for removal of unwanted material from an additively manufactured object by application of sonic energy are disclosed. Application of sound at specific frequencies, specific amplitudes and specific waveforms to specific materials causes physical displacement of such materials. When applied to objects formed by additive manufacturing and unwanted material formed with such objects, the displacement causes the unwanted material to break away from the object. Advantageously, the unwanted material removed from the additively manufactured object can be recycled.
    Type: Application
    Filed: July 9, 2020
    Publication date: September 8, 2022
    Applicant: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Publication number: 20220266517
    Abstract: An apparatus and method for removing support material from and/or smoothing surfaces of an additively manufactured part (the “AM part”) is disclosed. The apparatus may include a chamber, a support surface within the chamber, one or more nozzles within the chamber, a tank positioned below the nozzles, and a diverter positioned between the nozzles and the tank. The support surface may be configured to support the AM part and may have one or more openings configured to allow the fluid to pass through the opening(s). The nozzles may be configured to spray a fluid at the AM part, and the spray may be an atomized or semiatomized spray of the fluid. The diverter comprises an umbrella or a diverter shield and diverts sprayed fluid from directly impacting the fluid being collected in the tank, whereby foaming of the fluid in the tank is reduced.
    Type: Application
    Filed: August 5, 2020
    Publication date: August 25, 2022
    Applicant: PostProcess Technologies, Inc.
    Inventors: Matthew J. Noble, Nicholas Cultrara, Daniel Joshua Hutchinson, Rich Caplow, Robert Bosinski, Rowan Paris, Michael Valvo
  • Publication number: 20220241864
    Abstract: Methods using formulations for processing a manufactured metal or metal-alloy object, in particular a metal or metal-alloy object manufactured by an additive manufacturing process, are disclosed. Methods, systems and equipment for using the formulations to remove excess materials from the surface, remove support materials, and/or modify the surface of a metal or metal-alloy manufactured object are also disclosed.
    Type: Application
    Filed: June 18, 2020
    Publication date: August 4, 2022
    Applicant: PostProcess Technologies, Inc.
    Inventors: Matthew J. Noble, Daniel Joshua Hutchinson
  • Patent number: 11396608
    Abstract: Described are finishing solutions for removing support material and finishing 3D-printed objects. The finishing solution may contain a base (e.g., an aqueous base), an optional first caustic agent, an optional second caustic agent, an optional third caustic agent, an optional emulsifier, a polyol, a first antifoaming agent, an optional second antifoaming agent, and water. Also described are methods of using the finishing solution described herein.
    Type: Grant
    Filed: June 26, 2019
    Date of Patent: July 26, 2022
    Assignee: PostProcess Technologies, Inc.
    Inventors: Daniel Joshua Hutchinson, Marc Farfaglia, Cassidy Grant, Matthew J. Noble
  • Patent number: 11358336
    Abstract: A machine for washing and removing substrate material for parts produced by a 3D printer. The machine includes a housing having a working chamber and a disposal chamber. The machine has at least one inlet in fluid communication with the working chamber. The disposal chamber is disposed adjacent to the working chamber. A dividing wall is disposed between the working chamber and the disposal chamber. A pump conveys a working fluid to the at least one inlet in the working chamber. The disposal chamber and the working chamber are disposed in fluid communication via a passageway such that working fluid passes from the working chamber to the disposal chamber. The machine may also include an ultrasonic generator for generating ultrasonic vibrations within the working chamber and a heater for warming the working fluid.
    Type: Grant
    Filed: May 16, 2017
    Date of Patent: June 14, 2022
    Assignee: PostProcess Technologies, Inc.
    Inventor: Daniel J. Hutchinson
  • Publication number: 20220097303
    Abstract: A method for removing substrate material from a part produced by a 3-D printer. The machine includes a housing having a working chamber defined therein. A spray header is disposed along at least a portion of the perimeter of the working chamber. A pump is configured and arranged to convey a fluid at varying pressures through the spray header. The fluid contacts the part and then flows to the bottom of the working chamber to a fluid outlet.
    Type: Application
    Filed: December 8, 2021
    Publication date: March 31, 2022
    Applicant: PostProcess Technologies, Inc.
    Inventors: Daniel J. Hutchinson, Scott Alexander Gilmour, Adam Michael Moehlau, Joshua J. Yagy, Joseph M. McMahon
  • Publication number: 20220040929
    Abstract: Methods and systems according to the invention may be used to modify a manufacturing plan for an object manufactured by an additive manufacturing process. A digital representation of a desired object and a manufacturing plan may be compared to manufacturing information generated via an evaluation of such an object. Based on that comparison, the manufacturing plan may be modified so that that object or a subsequent object is highly similar to the desired object.
    Type: Application
    Filed: September 11, 2021
    Publication date: February 10, 2022
    Applicant: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Publication number: 20220032544
    Abstract: A process for removing support material from a part made by an additive manufacturing process is disclosed. The part may be arranged in a media filled tank. Ultrasonic waves are directed for the part and/or support material. Ultrasonic waves from an ultrasonic transducer are applied to a part or support material and cause the part to vibrate. The frequency of the ultrasonic energy may be tuned to cause the part and/or the support material to vibrate at its resonant frequency. The support material may have different properties, such as density, geometry, material, or porosity. Such differences may allow the support material to resonate in response to the applied ultrasonic energy waves at a different ultrasonic frequency than, the part itself.
    Type: Application
    Filed: August 26, 2021
    Publication date: February 3, 2022
    Applicant: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Patent number: 11225023
    Abstract: A machine for removing substrate material from a part produced by a 3-D printer. The machine includes a housing having a working chamber defined therein. A spray header is disposed along at least a portion of the perimeter of the working chamber. A pump is configured and arranged to convey a fluid at varying pressures through the spray header. The fluid contacts the part and then flows to the bottom of the working chamber to a fluid outlet.
    Type: Grant
    Filed: May 18, 2018
    Date of Patent: January 18, 2022
    Assignee: PostProcess Technologies, Inc.
    Inventors: Daniel J. Hutchinson, Scott Alexander Gilmour, Adam Michael Moehlau, Joshua J. Yagy, Joseph M. McMahon
  • Patent number: 11141922
    Abstract: Methods and systems according to the invention may be used to modify a manufacturing plan for an object manufactured by an additive manufacturing process. A digital representation of a desired object and a manufacturing plan may be compared to manufacturing information generated via an evaluation of such an object. Based on that comparison, the manufacturing plan may be modified so that that object or a subsequent object is highly similar to the desired object.
    Type: Grant
    Filed: March 11, 2019
    Date of Patent: October 12, 2021
    Assignee: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Patent number: 11110661
    Abstract: A process for removing support material from a part made by an additive manufacturing process is disclosed. The part may be arranged in a media filled tank. Ultrasonic waves are directed for the part and/or support material. Ultrasonic waves from an ultrasonic transducer are applied to a part or support material and cause the part to vibrate. The frequency of the ultrasonic energy may be tuned to cause the part and/or the support material to vibrate at its resonant frequency. The support material may have different properties, such as density, geometry, material, or porosity. Such differences may allow the support material to resonate in response to the applied ultrasonic energy waves at a different ultrasonic frequency than, the part itself.
    Type: Grant
    Filed: November 15, 2017
    Date of Patent: September 7, 2021
    Assignee: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson
  • Patent number: 10850449
    Abstract: An apparatus and method for removing support material from and/or smoothing surfaces of an additively manufactured part (the “AM part”) is disclosed. The apparatus may include a chamber, a support surface within the chamber, and one or more nozzles within the chamber. The nozzles may be the same size or different sizes. The support surface may be configured to support the AM part. The support surface may have one or more openings sized and configured to allow the fluid to pass through the opening(s). The nozzles may be configured to spray a fluid at the AM part, and the spray may be an atomized or semi-atomized spray of the fluid.
    Type: Grant
    Filed: December 26, 2018
    Date of Patent: December 1, 2020
    Assignee: PostProcess Technologies, Inc.
    Inventors: Daniel Joshua Hutchinson, Marc Farfaglia
  • Patent number: 10737440
    Abstract: An apparatus and method for removing support material from a part formed by three-dimensional (3D) printing. The support removal machine contains a tank for submersion of a 3D printed part into a liquid mass. The liquid mass circulates in the tank in a controlled manner such that submerged parts remain centrally suspended in the tank, regardless of the material, density and geometry comprising the part. The part circulates and rotates in conjunction with the rotational flow of the liquid mass for uniform exposure to means of support removal. During rotation, the part may be subjected to multiple means of agitation that include heat, chemical and ultrasonic, in order to optimize energy use and maximize efficiency of the removal of support material.
    Type: Grant
    Filed: July 23, 2019
    Date of Patent: August 11, 2020
    Assignee: PostProcess Technologies, Inc.
    Inventor: Daniel Joshua Hutchinson