Patents Assigned to Thermwood Corporation
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Patent number: 11969936Abstract: An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.Type: GrantFiled: March 22, 2023Date of Patent: April 30, 2024Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay
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Publication number: 20240123669Abstract: A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded materiaLType: ApplicationFiled: December 5, 2023Publication date: April 18, 2024Applicant: Thermwood CorporationInventor: Kenneth J. SUSNJARA
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Publication number: 20240100773Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: ApplicationFiled: December 5, 2023Publication date: March 28, 2024Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Patent number: 11931932Abstract: A mold assembly for producing a part includes a first section, a second section movably coupled to the first section, and a cavity defined by the first section and the second section, the cavity being shaped to receive a part while the first section and the second section are movably coupled to each other. The mold assembly includes a joint formed by adjacent surfaces of the first section and the second section and a seal extending along the joint.Type: GrantFiled: November 2, 2021Date of Patent: March 19, 2024Assignee: Thermwood CorporationInventor: Kenneth J. Susnjara
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Patent number: 11911953Abstract: An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.Type: GrantFiled: July 1, 2021Date of Patent: February 27, 2024Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Scott G. Vaal
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Publication number: 20240059006Abstract: An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.Type: ApplicationFiled: October 30, 2023Publication date: February 22, 2024Applicant: Thermwood CorporationInventor: Kenneth J. SUSNJARA
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Publication number: 20240017489Abstract: A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.Type: ApplicationFiled: July 14, 2023Publication date: January 18, 2024Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Scott G. VAAL, Nicolas C. VOTE
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Patent number: 11872752Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: GrantFiled: February 24, 2023Date of Patent: January 16, 2024Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Patent number: 11865760Abstract: A machine and method of forming an article generally comprising extruding a molten bead of thermoplastic material along x, y and z axes in forming an article consisting of a strata of such material, and passing a roller over each applied portion of such molten bead to compress such bead portion, enhancing the fusion of engaging plies of such extruded material.Type: GrantFiled: October 7, 2022Date of Patent: January 9, 2024Assignee: Thermwood CorporationInventor: Kenneth J. Susnjara
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Patent number: 11865788Abstract: An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.Type: GrantFiled: March 8, 2023Date of Patent: January 9, 2024Assignee: Thermwood CorporationInventor: Kenneth J. Susnjara
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Patent number: 11850789Abstract: An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.Type: GrantFiled: June 3, 2022Date of Patent: December 26, 2023Assignee: Thermwood CorporationInventor: Kenneth Susnjara
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Patent number: 11833752Abstract: An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.Type: GrantFiled: June 23, 2021Date of Patent: December 5, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay, Scott G. Vaal
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Publication number: 20230321899Abstract: An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.Type: ApplicationFiled: May 30, 2023Publication date: October 12, 2023Applicant: Thermwood CorporationInventor: Kenneth J. SUSNJARA
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Publication number: 20230302721Abstract: An additive manufacturing apparatus an extruder configured to receive material, a work surface extending so as to define a plane for receiving one or more layers of the material, an applicator assembly secured at a downstream portion of the additive manufacturing apparatus, a nozzle connected to the applicator assembly, the nozzle being configured to receive the material from the extruder and deposit the material on the work surface, and an actuator configured to displace the work surface in a movement direction, wherein the movement direction forms an acute angle with the plane.Type: ApplicationFiled: March 8, 2023Publication date: September 28, 2023Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Brian S. SMIDDY, Jonathan L. FUQUAY
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Patent number: 11724453Abstract: A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.Type: GrantFiled: December 22, 2021Date of Patent: August 15, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Scott G. Vaal, Nicolas C. Vote
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Patent number: 11701818Abstract: An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.Type: GrantFiled: April 28, 2022Date of Patent: July 18, 2023Assignee: Thermwood CorporationInventor: Kenneth J. Susnjara
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Publication number: 20230219296Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: ApplicationFiled: February 24, 2023Publication date: July 13, 2023Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Nicolas VOTE, Robert GAESSER, Brian S. SMIDDY, Scott G. VAAL
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Publication number: 20230219285Abstract: An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.Type: ApplicationFiled: March 22, 2023Publication date: July 13, 2023Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Brian S. SMIDDY, John FUQUAY
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Publication number: 20230219301Abstract: An additive manufacturing method includes providing a polymeric material and changing a cooling rate of the polymeric material by adding a second material to the polymeric material. The additive manufacturing method also includes providing the polymeric material and the added second material to an additive manufacturing apparatus and depositing the polymeric material, having the changed cooling rate, with the additive manufacturing apparatus at a deposition rate that is based at least in part on the changed cooling rate of the polymeric material.Type: ApplicationFiled: March 8, 2023Publication date: July 13, 2023Applicant: Thermwood CorporationInventor: Kenneth J. SUSNJARA
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Patent number: 11628614Abstract: An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.Type: GrantFiled: March 4, 2022Date of Patent: April 18, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay