Patents by Inventor J. Samuel Batchelder

J. Samuel Batchelder 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).

  • Publication number: 20210016495
    Abstract: A print assembly for use in an additive manufacturing system to print three-dimensional parts, which includes a coarse positioner, a fine positioner, and a liquefier assembly, where a portion of the liquefier assembly is operably mounted to the fine positioner such that the fine positioner is configured to move the portion of the liquefier assembly relative to the coarse positioner.
    Type: Application
    Filed: October 1, 2020
    Publication date: January 21, 2021
    Inventors: J. Samuel Batchelder, William J. Swanson
  • Patent number: 10889068
    Abstract: A 3D printer is configured to print a 3D part. The 3D printer includes a print head carried by a head gantry and configured to operably move the print head along planar tool paths. The 3D printer includes at least one head gantry actuator coupled to the head gantry and configured to move the print head in a plane and a print head actuator coupled to the print head and configured to move the print head in a direction substantially orthogonal to the plane. A sensor is fixedly mounted to the print head and configured to output a first signal that is directly or indirectly related to an acceleration of the print head, and a gyroscope is fixedly mounted to the print head and configured to output a second signal related to a rotational position of the print head.
    Type: Grant
    Filed: October 6, 2016
    Date of Patent: January 12, 2021
    Assignee: Stratasys, Inc.
    Inventors: J. Samuel Batchelder, William J. Swanson
  • Patent number: 10888908
    Abstract: A magnetically throttled liquefier assembly for use in an additive manufacturing system and configured to heat a metal-based alloy to an extrudable state includes an array of magnets to generate a magnetic field in order to induce a viscosity in the heated metal-based alloy and to control the flow rate of the heated metal-based alloy through the liquefier for extrusion and the building of a three-dimensional object with the metal-based alloy.
    Type: Grant
    Filed: September 17, 2018
    Date of Patent: January 12, 2021
    Assignee: Stratasys, Inc.
    Inventors: J. Samuel Batchelder, Robert L. Zinniel
  • Patent number: 10889044
    Abstract: A method of producing a part printed in a layer-wise manner includes providing a pre-fabricated starter piece with a first course of loops and printing a layer of a part by extruding one or more flowable thermoplastic materials about the existing course of loops such that an upper surface of the layer is at a selected height on the existing course of loops. The method includes knitting a next course of loops to the existing course of loops to form a portion of an internal woven reinforcement network, and printing a next layer of the part by extruding one or more flowable thermoplastic materials about the next course of loops such that an upper surface of the next layer is at a selected height on the next course of loops, wherein the next course of loops extends above the structure being printed and may function as an existing course of loops for subsequent knitting steps.
    Type: Grant
    Filed: January 11, 2019
    Date of Patent: January 12, 2021
    Assignee: Stratasys, Inc.
    Inventors: J. Samuel Batchelder, S. Scott Crump
  • Publication number: 20200368964
    Abstract: Disclosed are selective deposition-based additive manufacturing systems (10) and methods for printing a 3D part (26). Layers of a powder material (22) are developed using one or more electrostatographic engines (12a-d). The layers (22) are transferred for deposition on a part build surface (88). For each of the layers (22), the part build surface (88) is pre-heated by impinging a first heat transfer liquid (74) toward the part build surface (88), for example using a solder fountain. The developed layer (22) is pressed into contact with the heated part build surface (88) to heat the developed layer (22) to a flowable state and form a new part build surface (88) which is fully consolidated. The new part build surface (88) is then rapidly cooled to remove the heat energy added during heating step before repeating the steps for the next developed layer (22).
    Type: Application
    Filed: February 1, 2019
    Publication date: November 26, 2020
    Inventor: J. Samuel Batchelder
  • Publication number: 20200338813
    Abstract: Disclosed are selective deposition based additive manufacturing systems (10) and methods for printing a 3D part. Layers of a powder material (22) are developed using one or more electrostatography-based engines (12). The layers (22) are transferred for deposition on a part build surface. For each of the layers (22), the part build surface is heated to a temperature within a range between a flowable temperature and a thermal oxidation threshold to form a flowable part build surface, and the developed layer (22) is pressed into contact with the flowable build surface (88) to heat the developed layers (22) to a flowable state and form a new part build surface (88) which is fully consolidated. The new part build surface (88) is then cooled to remove the heat energy added during heating step before repeating the steps for the next developed layer.
    Type: Application
    Filed: December 29, 2017
    Publication date: October 29, 2020
    Inventors: Chris Counts, J. Samuel Batchelder
  • Publication number: 20200338815
    Abstract: A method of selective deposition-based additive manufacturing includes conveying a layer (28) of material to previously built layers (22) of material. A determination is made as to whether at least one of the conveyed layers (28) of material and a top previously built layer (22) of material contains an unsupported portion (302). When at least one of the conveyed layer (28) of material and the top previously built layer (22) of material contains an unsupported portion, a first set of steps (306, 408, 506) are used to transfer the conveyed layer (28) of material to the top previously built layer (22) of material. When neither of the conveyed layer (28) of material and the top previously built layer (22) of material contains an unsupported portion, a second set of steps (304, 406, 504) are used to transfer the conveyed layer (28) of material to the top previously built layer (22) of material.
    Type: Application
    Filed: December 29, 2017
    Publication date: October 29, 2020
    Inventors: J. Samuel Batchelder, Arun Chowdry, Chris Anton
  • Publication number: 20200331197
    Abstract: A print assembly 18 for use in an additive manufacturing system 10 to print three-dimensional parts 12, which includes a coarse positioner 40, a fine positioner 42, and a liquefier assembly 20, where a portion of the liquefier assembly 20 is operably mounted to the fine positioner 42 such that the fine positioner 42 is configured to move the portion of the liquefier assembly 20 relative to the coarse positioner 40.
    Type: Application
    Filed: July 2, 2020
    Publication date: October 22, 2020
    Inventors: J. Samuel Batchelder, William J. Swanson
  • Patent number: 10792908
    Abstract: In a method of producing a 3D part using an electrophotography-based additive manufacturing system, a plurality of layers of a powder-based material are developed using at least one electrophotography (EP) engine. The developed layers are transferred to a transfer medium. The layers on the transfer medium are dried by heating the layers without fully fusing the powder-based material to itself using a dryer. This reduces a water content of the layers. The dried layers are heated on the transfer medium to at least a fusion temperature, at which the power-based material fuses together, using a pre-transfusion heater. The dried layers are then transfused together on a build platform using a transfusion assembly to build the part in a layer-by-layer manner.
    Type: Grant
    Filed: December 21, 2016
    Date of Patent: October 6, 2020
    Assignee: Evolve Additive Solutions, Inc.
    Inventors: J. Samuel Batchelder, Arun Chowdry, Steven A. Chillscyzn
  • Publication number: 20200307087
    Abstract: Embodiments herein relate to substrates for use in a selective toner electrophotographic process (STEP) additive manufacturing system. The substrates include a build platform for use in STEP additive manufacturing system, the build platform comprising a build substrate for receiving a build material deposited by a STEP process; wherein the platform has selected thermal properties, such as within 30 percent of the build material to be deposited onto the substrate.
    Type: Application
    Filed: February 20, 2020
    Publication date: October 1, 2020
    Inventors: Chris Counts, J. Samuel Batchelder
  • Patent number: 10759107
    Abstract: A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.
    Type: Grant
    Filed: April 19, 2019
    Date of Patent: September 1, 2020
    Assignee: STRATASYS, INC.
    Inventors: J. Samuel Batchelder, William J. Swanson, S. Scott Crump
  • Patent number: 10744753
    Abstract: A print assembly for use in an additive manufacturing system to print three-dimensional parts, which includes a coarse positioner, a fine positioner, and a liquefier assembly, where a portion of the liquefier assembly is operably mounted to the fine positioner such that the fine positioner is configured to move the portion of the liquefier assembly relative to the coarse positioner.
    Type: Grant
    Filed: September 28, 2015
    Date of Patent: August 18, 2020
    Assignee: STRATASYS, INC.
    Inventors: J. Samuel Batchelder, William J. Swanson
  • Publication number: 20200223121
    Abstract: A method of producing a part printed in a layer-wise manner includes providing a pre-fabricated starter piece with a first course of loops and printing a layer of a part by extruding one or more flowable thermoplastic materials about the existing course of loops such that an upper surface of the layer is at a selected height on the existing course of loops. The method includes knitting a next course of loops to the existing course of loops to form a portion of an internal woven reinforcement network, and printing a next layer of the part by extruding one or more flowable thermoplastic materials about the next course of loops such that an upper surface of the next layer is at a selected height on the next course of loops, wherein the next course of loops extends above the structure being printed and may function as an existing course of loops for subsequent knitting steps.
    Type: Application
    Filed: January 11, 2019
    Publication date: July 16, 2020
    Inventors: J. Samuel Batchelder, S. Scott Crump
  • Publication number: 20200198229
    Abstract: An electrostatic-based layer-wise manufacturing system (e.g., 200; 200-1; 250; 282; 300) decouples a layer imaging process from a layer transfusion process.
    Type: Application
    Filed: July 31, 2018
    Publication date: June 25, 2020
    Inventors: Steven A. Chillscyzn, Arun Chowdry, J. Samuel Batchelder
  • Publication number: 20200198228
    Abstract: An electrophotography-based additive manufacturing system (e.g., 10; 100; 200; 300; 350; 500; 700) having at least one electrophotography (EP) or electrostatographic engine (e.g., 12; 12p; 12s; 612p; 612p; 712-1; 712-2) and being configured such that a plurality of independently movable parts is built in parallel at a plurality of decoupled processing stations.
    Type: Application
    Filed: July 31, 2018
    Publication date: June 25, 2020
    Inventors: Steven A. Chillscyzn, J. Samuel Batchelder
  • Patent number: 10682807
    Abstract: An additive manufacturing system and process for producing three-dimensional parts, which includes forming layers of the three-dimensional part from a part material at a first resolution, and ablating selected voxels of the formed layers with a laser beam at a second resolution that is higher than the first resolution.
    Type: Grant
    Filed: April 4, 2018
    Date of Patent: June 16, 2020
    Assignee: STRATASYS, INC.
    Inventor: J. Samuel Batchelder
  • Patent number: 10675858
    Abstract: A method of printing a part in an additive manufacturing system includes printing a support structure for the part, printing a boundary surrounding the support structure, and printing the part on the support structure. An additive manufacturing system for printing a three-dimensional part includes a transfer medium configured to receive and transfer imaged layers of a thermoplastic-based powder for a boundary, a thermoplastic-based powder for a support, and a thermoplastic-based powder for the part from at least two imaging engines, a heater configured to heat the imaged layers on the transfer medium to at least a fusion temperature of the thermoplastic-based powder, and a layer transfusion assembly including a build platform, the layer transfusion assembly being configured to transfuse the heated layers in a layer-by-layer manner onto the build platform to print the three-dimensional part.
    Type: Grant
    Filed: December 15, 2016
    Date of Patent: June 9, 2020
    Assignee: Evolve Additive Solutons, Inc.
    Inventors: J. Samuel Batchelder, S. Scott Crump
  • Patent number: 10670019
    Abstract: A pump assembly for use in an additive manufacturing system includes a viscosity pump having a first end and a second end wherein the first end has a cross sectional area greater than a cross sectional area of the second end. The viscosity pump has a conical shaped inner surface defining a pump chamber, an inlet proximate the first end and an outlet proximate the second end. The viscosity pump includes an impeller having an axis of rotation, where the impeller has a shaft positioned through the first end of the first housing and into the pump chamber. The impeller includes a distal tip-end at a distal end of the shaft wherein the impeller is configured to be axially displaced within the pump chamber of the viscosity pump parallel to the axis of rotation. An actuator is coupled to a proximal end of the impeller, wherein the actuator is configured to move the impeller parallel to the axis of rotation.
    Type: Grant
    Filed: October 28, 2016
    Date of Patent: June 2, 2020
    Assignee: STRATASYS, INC.
    Inventors: Robert L. Zinniel, J. Samuel Batchelder
  • Publication number: 20200149269
    Abstract: A large-scale additive manufacturing system for printing a structure includes an extrusion system and a knitting system. The extrusion system includes a nozzle configured to receive a supply of structural material and to selectively dispense the structural material in flowable form, and a first gantry configured to move the nozzle along toolpaths defined according to a structure to be printed such that structural material may be dispensed along the toolpaths to print a series of structural layers, wherein the series of structural layers bond together to form all or a portion of the structure.
    Type: Application
    Filed: November 13, 2018
    Publication date: May 14, 2020
    Inventors: S. Scott Crump, J. Samuel Batchelder, Susan M Hayes Jacobson
  • Publication number: 20200079008
    Abstract: A method for making a three-dimensional (3D) part with an electrostatographic based additive manufacturing system includes developing a first layer of a powder material using at least one electrostatographic engine, supporting the developed first layer on a transfer medium, adjusting a first layer thermal profile of the developed first layer with a first thermal flux device, adding thermal energy to a part thermal profile that includes a bonding region of previously accumulated layers of the 3D part, transfusing the developed first layer on the bonding region of the previously accumulated layers of the 3D part, and removing thermal energy from the part thermal profile. A transfusion temperature at a start of the transfusing step can be equal to or greater than a transfusion threshold temperature, where the transfusion temperature is an average of the first layer thermal profile and the part thermal profile in the bonding region.
    Type: Application
    Filed: September 5, 2019
    Publication date: March 12, 2020
    Inventors: Arun Chowdry, James W. Comb, Chris Counts, J. Samuel Batchelder