Patents Assigned to Thermwood Corporation
  • Patent number: 10688719
    Abstract: 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: Grant
    Filed: June 28, 2019
    Date of Patent: June 23, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
  • Patent number: 10668664
    Abstract: 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 plurality of sections to manufacture the part.
    Type: Grant
    Filed: November 9, 2018
    Date of Patent: June 2, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal, Nicolas C. Vote
  • Patent number: 10668657
    Abstract: 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: Grant
    Filed: May 3, 2019
    Date of Patent: June 2, 2020
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • Publication number: 20200147876
    Abstract: In one embodiment of the present disclosure, 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 plurality of sections to manufacture the part.
    Type: Application
    Filed: November 9, 2018
    Publication date: May 14, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal, Nicolas C. Vote
  • Publication number: 20200139615
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.
    Type: Application
    Filed: November 7, 2019
    Publication date: May 7, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Scott G. Vaal
  • Patent number: 10632683
    Abstract: A method for thermal compensation during an additive manufacturing process. In some aspects, the method may include receiving, at a CNC machine, information relating to a material used in the additive manufacturing process, wherein the received information includes at least a Coefficient for Thermal Expansion (CTE) for the material. The method may further include modifying a distance of travel for a first pre-programmed tool path based on at least the Coefficient for Thermal Expansion (CTE).
    Type: Grant
    Filed: February 12, 2019
    Date of Patent: April 28, 2020
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • Patent number: 10611073
    Abstract: 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: Grant
    Filed: December 28, 2015
    Date of Patent: April 7, 2020
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • Publication number: 20200086561
    Abstract: An exemplary additive manufacturing system may include an extruder having an opening dimensioned to receive a material. The extruder also may have a barrel and a screw within the barrel. The screw may have a diameter ranging between about 20 mm and about 150 mm and the barrel extends along a longitudinal axis. The system may include one or more heaters positioned along at least a portion of the barrel. As the material passes through the barrel, the one or more heaters may at least partially melt the material. The system may further include a gear pump in fluid communication with the barrel for receiving the at least partially melted material. Additionally, the system may include a nozzle in fluid communication with the gear pump for depositing the at least partially melted material. The system also may include a vertical worktable.
    Type: Application
    Filed: November 7, 2019
    Publication date: March 19, 2020
    Applicant: Thermwood Corporation.
    Inventor: Scott G. VAAL
  • Publication number: 20200061905
    Abstract: 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: Application
    Filed: September 17, 2019
    Publication date: February 27, 2020
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal
  • Patent number: 10569521
    Abstract: In one embodiment, an additive manufacturing method including the steps of positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed; and depositing a flowable material on at least some of the plurality of pellets.
    Type: Grant
    Filed: April 5, 2016
    Date of Patent: February 25, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth Susnjara, Scott Vaal
  • Patent number: 10569523
    Abstract: In one embodiment, an additive manufacturing method including the steps of positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed; depositing a first plurality of layers of a flowable material on at least some of the plurality of pellets; and depositing a second plurality of layers of the flowable material on the first plurality of layers.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: February 25, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth Susnjara, Scott Vaal
  • Publication number: 20200055299
    Abstract: 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: Application
    Filed: October 23, 2019
    Publication date: February 20, 2020
    Applicant: Thermwood Corporation
    Inventor: Kenneth SUSNJARA
  • Patent number: 10549477
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include determining x and y coordinates for a tool path of an additive manufacturing machine, and calculating an angle of the tool path. The method may also include determining a position of a compression roller relative to the angle of the tool path, and moving the compression roller to position the compression roller relative to the angle of the tool path.
    Type: Grant
    Filed: February 17, 2017
    Date of Patent: February 4, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Nicolas Vote
  • Patent number: 10532512
    Abstract: An additive manufacturing system may include an extruder. The extruder may include a barrel having a bore. Additionally, the extruder may include an extruder screw at least partially received within the bore of the barrel. The additive manufacturing system also may include a gear pump fluidly coupled to the bore of the barrel. The extruder screw may extend at least partially into the gear pump.
    Type: Grant
    Filed: June 7, 2018
    Date of Patent: January 14, 2020
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy
  • Publication number: 20200009851
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.
    Type: Application
    Filed: September 17, 2019
    Publication date: January 9, 2020
    Applicant: Thermwood Corporation
    Inventor: Kenneth J. SUSNJARA
  • Publication number: 20190375148
    Abstract: An additive manufacturing system may include an extruder. The extruder may include a barrel having a bore. Additionally, the extruder may include an extruder screw at least partially received within the bore of the barrel. The additive manufacturing system also may include a gear pump fluidly coupled to the bore of the barrel. The extruder screw may extend at least partially into the gear pump.
    Type: Application
    Filed: June 7, 2018
    Publication date: December 12, 2019
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy
  • Patent number: 10500785
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.
    Type: Grant
    Filed: February 17, 2017
    Date of Patent: December 10, 2019
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal
  • Patent number: 10500788
    Abstract: An exemplary additive manufacturing system may include an extruder having an opening dimensioned to receive a material. The extruder also may have a barrel and a screw within the barrel. The screw may have a diameter ranging between about 20 mm and about 150 mm and the barrel extends along a longitudinal axis. The system may include one or more heaters positioned along at least a portion of the barrel. As the material passes through the barrel, the one or more heaters may at least partially melt the material. The system may further include a gear pump in fluid communication with the barrel for receiving the at least partially melted material. Additionally, the system may include a nozzle in fluid communication with the gear pump for depositing the at least partially melted material. The system also may include a vertical worktable.
    Type: Grant
    Filed: November 7, 2017
    Date of Patent: December 10, 2019
    Assignee: Thermwood Corporation
    Inventor: Scott G. Vaal
  • Patent number: 10486413
    Abstract: 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: Grant
    Filed: May 17, 2019
    Date of Patent: November 26, 2019
    Assignee: Thermwood Corporation
    Inventor: Kenneth Susnjara
  • Patent number: 10457036
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing method may include forming a part using additive manufacturing. The method may also include bringing the part to a first temperature, measuring the part along at least three axes at the first temperature, bringing the part to a second temperature, different than the first temperature, and measuring the part along the at least three axes at the second temperature. The method may further include comparing the size of the part at the first and second temperatures to calculate a coefficient of thermal expansion, generating a tool path that compensates for the coefficient of thermal expansion, bringing the part to the first temperature, and trimming the part while the part is at the first temperature using the tool path.
    Type: Grant
    Filed: November 6, 2017
    Date of Patent: October 29, 2019
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara