Patents by Inventor Gregory Thomas Mark

Gregory Thomas Mark has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11237542
    Abstract: In a method for additive manufacturing, a multi-strand core reinforced filament including a flowable matrix material and substantially continuous reinforcing strands extending in a direction parallel to a length of the filament is supplied. A first consolidated composite swath of a height less than ½ the width of the filament is deposited in a first reinforcement formation including at least one straight path and at least one curved path against a deposition surface, and a second consolidated composite swath of a height less than ½ the width of the filament is deposited in a second reinforcement formation against the first consolidated composite swath. Each deposition flows the matrix material and applies an ironing force to spread the reinforcing strands within the filament against the underlying surface and/or previously deposited swath.
    Type: Grant
    Filed: November 17, 2015
    Date of Patent: February 1, 2022
    Assignee: MARKFORGED, INC.
    Inventors: Gregory Thomas Mark, Rick Bryan Woodruff, David Steven Benhaim, Abraham Lawrence Parangi, Benjamin Tsu Sklaroff
  • Publication number: 20220001587
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.
    Type: Application
    Filed: September 16, 2021
    Publication date: January 6, 2022
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz
  • Publication number: 20220001600
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into a conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.
    Type: Application
    Filed: September 16, 2021
    Publication date: January 6, 2022
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz
  • Publication number: 20210387416
    Abstract: In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.
    Type: Application
    Filed: February 24, 2021
    Publication date: December 16, 2021
    Inventor: Gregory Thomas Mark
  • Patent number: 11173550
    Abstract: According to one aspect, embodiments herein provide a method of reducing distortion in an additively manufactured part comprising forming a shrinking platform from a composite including metal particles embedded in a first matrix, forming shrinking supports from the composite, forming a part from the composite upon the shrinking platform and shrinking supports, forming an interior structure in at least one of the shrinking platform, the shrinking supports, and the part having a plurality of chambers with interconnections therebetween, forming from the shrinking platform, the sintering supports, and the part a portable assembly, and debinding the first matrix in the portable assembly to form a portable assembly in a brown state, wherein debinding the first matrix includes penetrating a fluid debinder into the interior structure of the at least one of the shrinking platform, the shrinking supports, and the part to debind the first matrix from within the interior structure.
    Type: Grant
    Filed: August 26, 2019
    Date of Patent: November 16, 2021
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Patent number: 11148409
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.
    Type: Grant
    Filed: November 16, 2015
    Date of Patent: October 19, 2021
    Assignee: MARKFORGED, INC.
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz
  • Publication number: 20210221054
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.
    Type: Application
    Filed: October 5, 2020
    Publication date: July 22, 2021
    Inventor: Gregory Thomas Mark
  • Patent number: 11065861
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to applying the filament from the conduit nozzle.
    Type: Grant
    Filed: November 16, 2015
    Date of Patent: July 20, 2021
    Assignee: MARKFORGED, INC.
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz
  • Publication number: 20210213534
    Abstract: Systems, apparatus and methods of additively manufacturing objects are disclosed. Specifically, provided herein are methods of heating objects having a particle-based support at least partially surrounding the object during portions of stages of the heating. Additionally, systems, apparatus, and methods for removing the particle-based support during heating, such that the object can continue heating to form a final part. Systems, apparatus, and methods for distributing the particle-based support to shore the objects through heating are disclosed. Systems, apparatus, and methods for removing the particle-based support are also disclosed herein.
    Type: Application
    Filed: January 11, 2021
    Publication date: July 15, 2021
    Inventors: Gregory Thomas Mark, Christopher Hoffmann, Benjamin Hodsdon Gallup, Maxim Seleznev, Michelle Ling Chao
  • Publication number: 20210197493
    Abstract: According to one aspect, embodiments of the invention provide a method of 3D printing, comprising depositing a model material in successive layers to form a part, the model material being a metal composite including greater than 50% by volume metal powder and less than 50% by volume a first removable binder, depositing the model material in successive layers to form a support structure adjacent the part, depositing a sinterable separation material between a surface of the part and a surface of the support structure, the sinterable separation material formed from 10-40% by volume ceramic powder and greater than 50% by volume a second removable binder, debinding the first removable binder of the model material and the second removable binder of the sinterable separation material, and sintering the part, the support structure, and the sinterable separation material at a temperature profile that sinters the model material and the sinterable separation material.
    Type: Application
    Filed: October 1, 2020
    Publication date: July 1, 2021
    Inventors: Gregory Thomas Mark, Rick Bryan Woodruff, Michelle Ling Chao
  • Publication number: 20210178691
    Abstract: A system, apparatus and methods of additively manufacturing an object is disclosed. Specifically, provided herein are systems and methods of distributing powder within a build chamber for a layer-by-layer binderjet process. Distributing powder including apparatus and methods for uniformly densifying powder within the build chamber are also disclosed herein.
    Type: Application
    Filed: December 14, 2020
    Publication date: June 17, 2021
    Inventors: Gregory Thomas Mark, Benjamin Hodsdon Gallup
  • Patent number: 11014305
    Abstract: According to one aspect, embodiments herein provide a method for in-process inspection of a 3D printed part with a 3D printer, comprising slicing a three dimensional model to define a plurality of shell volumes, for substantially each shell volume, generating a toolpath for depositing a printing material shell corresponding to the shell volume, transmitting, together with an identification, the toolpaths defining the printing material shells for deposition by a 3D printer, receiving, together with the identification, from the 3D printer a scanned surface profile of a printing material shell, and computing a process inspection including, according to the identification, a comparison between a received scanned surface profile and a toolpath defining a printing material shell.
    Type: Grant
    Filed: August 22, 2018
    Date of Patent: May 25, 2021
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Patent number: 10953610
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.
    Type: Grant
    Filed: October 16, 2018
    Date of Patent: March 23, 2021
    Assignee: MARKFORGED, INC.
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz
  • Patent number: 10953609
    Abstract: In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.
    Type: Grant
    Filed: March 15, 2017
    Date of Patent: March 23, 2021
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Publication number: 20200371509
    Abstract: Techniques for manufacturing optimization using a multi-tenant machine learning platform are disclosed. A method for manufacturing optimization includes: obtaining physical sensor data, by a manufacturing device associated with a tenant of a multi-tenant machine learning platform; determining, by a machine learning spoke system associated with the tenant, a machine learning parameter based on at least the physical sensor data; preventing exposure of the first physical sensor data of the first manufacturing device to any other tenant of the multi-tenant machine learning platform; transmitting the machine learning parameter from the machine learning spoke system to a machine learning hub system of the multi-tenant machine learning platform; and updating, by the machine learning hub system, a multi-tenant machine learning model based at least on the machine learning parameter.
    Type: Application
    Filed: May 26, 2020
    Publication date: November 26, 2020
    Inventor: Gregory Thomas Mark
  • Patent number: 10828698
    Abstract: In additive manufacturing, a composite build material filament and a release material filament are dropped from respective spools to a print head. Each of the composite build material filament and the release material filament includes a metal or ceramic powder plus a binder. On the spools and over the drop height, the filaments are heated to a temperature that flexes the filaments but does not soften them to a breaking point. The drop height is of similar linear scale to the build plate. The materials are debound and sintered.
    Type: Grant
    Filed: December 5, 2017
    Date of Patent: November 10, 2020
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Patent number: 10821662
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.
    Type: Grant
    Filed: August 6, 2018
    Date of Patent: November 3, 2020
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Publication number: 20200324461
    Abstract: According to one aspect, embodiments herein provide a 3-D printer comprising a composite filament supply, a build platen, a print head comprising a composite filament ironing tip and a heater, a plurality of actuators that move the print head and the build platen relative to one another in three degrees of freedom at a printing rate, at least one linear feed mechanism that advances the composite filament at a feed rate and drives the composite filament into the print head to deposit the composite filament, and a controller configured to operate the heater to heat the composite filament ironing tip to flow matrix material among axial fiber strands within the composite filament and operate the plurality of actuators to press the composite filament ironing tip against the composite filament and reshape the composite filament against one of the build platen and a composite filament previously deposited upon the build platen.
    Type: Application
    Filed: April 6, 2020
    Publication date: October 15, 2020
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz
  • Patent number: 10800108
    Abstract: According to one aspect, embodiments of the invention provide a method of 3D printing, comprising depositing a model material in successive layers to form a part, the model material being a metal composite including greater than 50% by volume metal powder and less than 50% by volume a first removable binder, depositing the model material in successive layers to form a support structure adjacent the part, depositing a sinterable separation material between a surface of the part and a surface of the support structure, the sinterable separation material formed from 10-40% by volume ceramic powder and greater than 50% by volume a second removable binder, debinding the first removable binder of the model material and the second removable binder of the sinterable separation material, and sintering the part, the support structure, and the sinterable separation material at a temperature profile that sinters the model material and the sinterable separation material.
    Type: Grant
    Filed: May 22, 2019
    Date of Patent: October 13, 2020
    Assignee: MARKFORGED, INC.
    Inventors: Gregory Thomas Mark, Rick Bryan Woodruff, Michelle Ling Chao
  • Patent number: 10717228
    Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.
    Type: Grant
    Filed: July 10, 2018
    Date of Patent: July 21, 2020
    Assignee: MARKFORGED, INC.
    Inventors: Gregory Thomas Mark, Antoni S. Gozdz