Patents Assigned to Thermwood Corporation
  • METHODS AND APPARATUS FOR PROCESSING AND DISPENSING MATERIAL DURING ADDITIVE MANUFACTURING
    Publication number: 20190322044
    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: Application
    Filed: June 28, 2019
    Publication date: October 24, 2019
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Nicolas VOTE, Robert GAESSER, Brian S. SMIDDY, Scott G. VAAL
  • Methods and apparatus for compressing material during additive manufacturing
    Patent number: 10449710
    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: Grant
    Filed: February 17, 2017
    Date of Patent: October 22, 2019
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Scott G. Vaal
  • APPARATUS AND METHODS FOR FABRICATING COMPONENTS
    Publication number: 20190270297
    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: May 17, 2019
    Publication date: September 5, 2019
    Applicant: Thermwood Corporation
    Inventor: Kenneth SUSNJARA
  • MACHINE AND METHOD FOR FORMING ARTICLES
    Publication number: 20190255752
    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: Application
    Filed: May 3, 2019
    Publication date: August 22, 2019
    Applicant: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • METHODS AND APPARATUS FOR THERMAL COMPENSATION DURING ADDITIVE MANUFACTURING
    Publication number: 20190248076
    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: Application
    Filed: February 12, 2019
    Publication date: August 15, 2019
    Applicant: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • Methods and apparatus for processing and dispensing material during additive manufacturing
    Patent number: 10377124
    Abstract: An additive manufacturing method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, the nozzle being 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. In one embodiment, the method includes actuating an extruder to form a flowable material, delivering the flowable material to a pump, sensing a pressure of the flowable material, and adjusting at least one of a speed of the extruder and a speed of the pump based on at least one of the sensed pressure and a rate of translation of the nozzle along one or more of the first, second, and third axes.
    Type: Grant
    Filed: August 31, 2016
    Date of Patent: August 13, 2019
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Scott G. Vaal
  • Apparatus and methods for fabricating components
    Patent number: 10336050
    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: March 7, 2016
    Date of Patent: July 2, 2019
    Assignee: Thermwood Corporation
    Inventor: Kenneth Susnjara
  • Machine and method for forming articles
    Patent number: 10286588
    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: April 11, 2018
    Date of Patent: May 14, 2019
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • APPARATUS AND METHODS FOR ADDITIVE MANUFACTURING AT AMBIENT TEMPERATURE
    Publication number: 20190134900
    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, 2017
    Publication date: May 9, 2019
    Applicant: Thermwood Corporation
    Inventor: Scott G. VAAL
  • Methods and apparatus for thermal compensation during additive manufacturing
    Patent number: 10245788
    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 14, 2018
    Date of Patent: April 2, 2019
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • APPARATUS AND METHODS FOR COMPRESSING MATERIAL DURING ADDITIVE MANUFACTURING
    Publication number: 20190077079
    Abstract: Embodiments of the present disclosure are drawn to an additive manufacturing system, which may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. An applicator head may surround at least a portion of a proximal region of the nozzle. The applicator head may include a housing, a cooling inlet for receiving a coolant into the housing, a cooling outlet configured to allow the coolant to exit the housing, and an air inlet. A roller may be mounted on the applicator head to one side of the outlet of the nozzle. The roller may include an air outlet, wherein a flow path connects the air inlet and the air outlet so that air enters the air inlet and exits the air outlet. The roller may also include a plurality of holes located on an external surface of the roller.
    Type: Application
    Filed: September 13, 2017
    Publication date: March 14, 2019
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Scott G. VAAL, Brian S. SMIDDY
  • APPARATUS AND METHOD FOR PRINTING LARGE THERMOPLASTIC PARTS DURING ADDITIVE MANUFACTURING
    Publication number: 20190077081
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder, the extruder having an opening dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle in fluid communication with the gear pump for depositing the at least partially melted material.
    Type: Application
    Filed: September 13, 2017
    Publication date: March 14, 2019
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Scott G. Vaal, Brian S. Smiddy, Jonathan I. Fuquay
  • METHODS AND APPARATUS FOR COMPENSATING FOR THERMAL EXPANSION DURING ADDITIVE MANUFACTURING
    Publication number: 20190001656
    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: November 6, 2017
    Publication date: January 3, 2019
    Applicant: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • Compression roller design and method for additive manufacturing
    Patent number: 10105894
    Abstract: An additive manufacturing system may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. The system also may include an applicator head surrounding at least a portion of the nozzle. Additionally, a roller may be mounted on the applicator head and rotatable about an axle. A coolant circuit may extend through at least a portion of the applicator head and through a lumen of the axle.
    Type: Grant
    Filed: April 11, 2018
    Date of Patent: October 23, 2018
    Assignee: Thermwood Corporation
    Inventor: Brian S. Smiddy
  • Apparatus and method for printing long composite thermoplastic parts on a dual gantry machine during additive manufacturing
    Patent number: 10071525
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary apparatus for fabricating components via additive manufacturing may include a programmable CNC machine. The CNC machine may comprise a first worktable extending in a first plane and a second worktable extending in a second plane, wherein the second plane is oriented at an angle relative to the first plane. At least one conveyor belt may be operably coupled to the first worktable. A printing gantry may be displaceable along a first axis of the CNC machine. The CNC machine may also comprise an applicator having a nozzle configured to deposit material on the second worktable.
    Type: Grant
    Filed: June 13, 2017
    Date of Patent: September 11, 2018
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy, Jonathan I. Fuquay
  • Apparatus and method for printing long composite thermoplastic parts on a dual gantry machine during additive manufacturing
    Patent number: 10065361
    Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary apparatus for fabricating components via additive manufacturing may include a programmable CNC machine. The CNC machine may comprise a first worktable extending in a first plane and a second worktable extending in a second plane, wherein the second plane is oriented at an angle relative to the first plane. At least one conveyor belt may be operably coupled to the first worktable. A printing gantry may be displaceable along a first axis of the CNC machine. The CNC machine may also comprise an applicator having a nozzle configured to deposit material on the second worktable.
    Type: Grant
    Filed: March 14, 2018
    Date of Patent: September 4, 2018
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian S. Smiddy, Jonathan I. Fuquay
  • Additive manufacturing apparatus
    Patent number: 10065360
    Abstract: A CNC machine including a worktable displaceable along y-axis, a gantry disposed along an x-axis, either fixed or displaceable along the y-axis, a carriage on such gantry displaceable along the x-axis and including a thermoplastic material extrusion conduit, a tool carrier mounted on such carriage displaceable along a z-axis, a dispersion conduit mounted on such tool carrier accommodating an applicator, means mounted on such applicator for extruding a molten bead of a thermoplastic material, a flexible hose interconnecting such molten material forming means and such applicator, a plurality of servomotors for linearly or rotationally displacing such components along or about such axes and a computer for controlling such component displacements.
    Type: Grant
    Filed: June 19, 2017
    Date of Patent: September 4, 2018
    Assignee: Thermwood Corporation
    Inventors: Kenneth J. Susnjara, Brian Scott Smiddy
  • Machine for forming thermoplastic articles and device utilized in the production thereof
    Patent number: 10059051
    Abstract: An assembly mountable on a machine including a gantry displaceable along an x-axis, a carriage mounted on such gantry displaceable along the y-axis, provided with means for extruding a beam of molten thermoplastic material, a tool carrier mounted on such carriage displaceable along a z-axis, a tool holder mounted on such tool carrier displaceable about a z-axis, a tool support shaft provided with an axis disposed in an x-y plane journalled in such tool holder and rotatable about the axis thereof, a dispenser conduit mounted on such shaft, perpendicular to such shaft axis, means on such dispenser conduit for ejection of a beam of molten thermoplastic material and a flexible hose with a first end supported on such carrier forming a rotary union with such material extrusion means, and a second end communicating with an inlet of such dispenser conduit.
    Type: Grant
    Filed: June 19, 2017
    Date of Patent: August 28, 2018
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • METHODS AND APPARATUS FOR CONTROLLING AN APPLICATOR HEAD DURING ADDITIVE MANUFACTURING
    Publication number: 20180236723
    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: Application
    Filed: February 17, 2017
    Publication date: August 23, 2018
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Nicolas VOTE
  • METHODS AND APPARATUS FOR COMPRESSING MATERIAL DURING ADDITIVE MANUFACTURING
    Publication number: 20180236722
    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: February 17, 2017
    Publication date: August 23, 2018
    Applicant: Thermwood Corporation
    Inventors: Kenneth J. SUSNJARA, Scott G. VAAL