Patents by Inventor Kareemullah Shaik

Kareemullah Shaik 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: 20250115989
    Abstract: An electrochemical-deposition printhead assembly includes a substrate made of an insulating material and including openings that extend from a top surface to a bottom surface of the substrate. The electrochemical-deposition printhead assembly also includes deposition anodes that include conductive material that fills the openings. The electrochemical-deposition printhead assembly additionally includes a backplane that is coupled to the substrate. The backplane includes a grid control circuit, which includes an array of row traces, an array of column traces, a row driver circuit, electrically coupled to the row traces, and a column driver circuit, electrically coupled to the column traces. The backplane also includes a power distribution circuit and deposition-control circuits aligned with a deposition grid. Each one of the deposition-control circuits is electrically coupled to the power distribution circuit, an associated one of the row traces, and an associated one of the column traces.
    Type: Application
    Filed: December 17, 2024
    Publication date: April 10, 2025
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, Kareemullah Shaik, Edward White
  • Publication number: 20250109519
    Abstract: Described herein are ECAM systems and methods of operating such systems or, more specifically, methods of determining the spacing between build plates and printheads before deposits contact the printheads. A method may comprise positioning a build plate and a printhead (e.g., comprising a copper deposit) at a set orientation relative to each other and for some time (e.g., to allow changes in the electrolyte between the build plate and the printhead and/or changes to the printhead's electrode surface). Thereafter, a measuring voltage is applied between each pixelated electrode of the printhead and a measuring reference plate (which may be the build plate or another plate) while obtaining one or more current values. These current values are then compared to the calibration data set to determine the distances between this electrode and the build plate or, more specifically, the deposit on the build plate.
    Type: Application
    Filed: September 27, 2024
    Publication date: April 3, 2025
    Inventors: Justin Pierce, Joshua Gillespie, Kareemullah Shaik, David Wong
  • Patent number: 12264405
    Abstract: Described herein are electrochemical additive manufacturing systems and methods of using such systems. In some examples, a method comprises flowing an electrolyte solution into the gap formed by an electrode array and a deposition electrode and depositing (electroplating) a target material onto the deposition electrode. The method also comprises changing one or more characteristics of the electrolyte solution within the system, e.g., to remove deposition byproducts, replenish consumed components, and/or change the solution composition to modify various properties of the deposited target material (e.g., composition, morphology) without major changeovers within the system. These electrolyte changes can be performed dynamically while the system continues to operate. The changed characteristics can be acid concentration, feedstock ion concentration, additive concentration, temperature, and flow rate.
    Type: Grant
    Filed: August 30, 2022
    Date of Patent: April 1, 2025
    Assignee: Fabric8Labs, Inc.
    Inventors: David Pain, Jeffrey Herman, Kareemullah Shaik, Andrew Edmonds
  • Patent number: 12257784
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Grant
    Filed: February 29, 2024
    Date of Patent: March 25, 2025
    Assignee: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman
  • Publication number: 20250059664
    Abstract: Printhead for a 3D manufacturing system that uses metal electrodeposition to construct parts; embodiments utilize a grid of anodes to achieve high quality parts with features that may be small and detailed. To support grids with thousands or millions of anodes, the printhead may use matrix control with row and column drivers similar to display backplanes. Unlike display backplanes where the design goal is to display images using minimal current, the printhead may be optimized for high current density for fast electrodeposition, and for anode longevity. Current density may exceed 1000 mA per cm-squared, at least an order of magnitude greater than that of display backplanes. Anode longevity may be enhanced by using relatively large anodes compared to the grid pitch of the printhead, by lengthening the conductive paths through anodes, or both. Embodiments may be constructed by adding anode and insulation layers on top of matrix-controlled switching circuits.
    Type: Application
    Filed: November 5, 2024
    Publication date: February 20, 2025
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, David Wirth, Kareemullah Shaik
  • Publication number: 20250059667
    Abstract: An electrochemical-deposition apparatus that includes a printhead, an electric-power supply circuit, a controller. The controller is configured to sequentially direct the electric-power supply circuit to establish a first electric current through an electrolytic solution, an initial electrode, and at least one of a plurality of individually addressable transitional electrodes of the printhead, direct the electric-power supply circuit to terminate the first electric current, and direct the electric-power supply circuit to either establish a second electric current through the electrolytic solution, at least the one of the plurality of individually addressable transitional electrodes, and a target electrode, or establish a third electric current through a second electrolytic solution, at least the one of the plurality of individually addressable transitional electrodes, and the target electrode.
    Type: Application
    Filed: August 23, 2024
    Publication date: February 20, 2025
    Inventors: Kareemullah Shaik, Andrew Edmonds, Ryan Nicholl, David Pain
  • Publication number: 20240417875
    Abstract: An electrochemical deposition system includes a cathode and a printhead. The printhead is spaced apart from the cathode, movable relative to the cathode, and comprises a plurality of deposition anodes. The system further comprises a capacitive sensor that includes a first electrically-conductive layer, at a known location relative to the cathode, and a second electrically-conductive layer, at a known location relative to the printhead. The system additionally includes a processor, electrically coupled with the capacitive sensor and configured to determine a distance between the cathode and the printhead in response to a capacitance of the capacitive sensor.
    Type: Application
    Filed: August 27, 2024
    Publication date: December 19, 2024
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, Ryan Nicholl, Kareemullah Shaik
  • Publication number: 20240384397
    Abstract: An electrochemical-deposition printhead assembly includes a substrate made of an insulating material and including openings that extend from a top surface to a bottom surface of the substrate. The electrochemical-deposition printhead assembly also includes deposition anodes that include conductive material that fills the openings. The electrochemical-deposition printhead assembly additionally includes a backplane that is coupled to the substrate. The backplane includes a grid control circuit, which includes an array of row traces, an array of column traces, a row driver circuit, electrically coupled to the row traces, and a column driver circuit, electrically coupled to the column traces. The backplane also includes a power distribution circuit and deposition-control circuits aligned with a deposition grid. Each one of the deposition-control circuits is electrically coupled to the power distribution circuit, an associated one of the row traces, and an associated one of the column traces.
    Type: Application
    Filed: April 24, 2024
    Publication date: November 21, 2024
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, Kareemullah Shaik, Edward White
  • Publication number: 20240368792
    Abstract: Printhead for a 3D manufacturing system that uses metal electrodeposition to construct parts; embodiments utilize a grid of anodes to achieve high quality parts with features that may be small and detailed. To support grids with thousands or millions of anodes, the printhead may use matrix control with row and column drivers similar to display backplanes. Unlike display backplanes where the design goal is to display images using minimal current, the printhead may be optimized for high current density for fast electrodeposition, and for anode longevity. Current density may exceed 1000 mA per cm-squared, at least an order of magnitude greater than that of display backplanes. Anode longevity may be enhanced by using relatively large anodes compared to the grid pitch of the printhead, by lengthening the conductive paths through anodes, or both. Embodiments may be constructed by adding anode and insulation layers on top of matrix-controlled switching circuits.
    Type: Application
    Filed: July 15, 2024
    Publication date: November 7, 2024
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, David Wirth, Kareemullah Shaik
  • Patent number: 12104270
    Abstract: A method of electroplating a target electrode comprises establishing a first electric current through an electrolytic solution, comprising a quantity of an electrically charged material, an initial electrode, and a transitional electrode, so that a quantity of the electrically charged material is converted to a quantity of an electrically neutral material, which is electroplated, as a deposit, onto the transitional electrode; and establishing a second electric current through the electrolytic solution, the transitional electrode, and the target electrode so that a quantity of the electrically neutral material from the deposit is converted to a quantity of the electrically charged material, which is dissolved into the electrolytic solution, and a quantity of the electrically charged material in the electrolytic solution is converted to a quantity of the electrically neutral material, which is electroplated onto the surface of the target electrode.
    Type: Grant
    Filed: May 3, 2023
    Date of Patent: October 1, 2024
    Assignee: FABRIC8LABS, INC.
    Inventors: Kareemullah Shaik, Andrew Edmonds, Ryan Nicholl, David Pain
  • Patent number: 12104264
    Abstract: An electrochemical deposition system includes a cathode and a printhead. The printhead is spaced apart from the cathode, movable relative to the cathode, and comprises a plurality of deposition anodes. The system further comprises a capacitive sensor that includes a first electrically-conductive layer, at a known location relative to the cathode, and a second electrically-conductive layer, at a known location relative to the printhead. The system additionally includes a processor, electrically coupled with the capacitive sensor and configured to determine a distance between the cathode and the printhead in response to a capacitance of the capacitive sensor.
    Type: Grant
    Filed: December 17, 2021
    Date of Patent: October 1, 2024
    Assignee: FABRIC8LABS, INC.
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, Ryan Nicholl, Kareemullah Shaik
  • Publication number: 20240304440
    Abstract: Described herein are protected electrode arrays and methods of fabricating thereof. Such electrode arrays can be used in electrochemical-additive manufacturing (ECAM) systems and other systems/applications. In some examples, a protected electrode array comprises an electrode-interface circuit and an interposer bonded to the circuit, e.g., using an adhesive layer. The interposer can include an interposer base formed from silicon, glass, and other like materials suitable for operating environments. The interposer base comprises vias, which are aligned with the circuit's electrode connectors, and interposer electrodes deposited within these vias and electrically coupled to the electrode connectors. In some examples, the interposer comprises a base cover and/or electrode covers positioned over the interposer base and the interposer electrodes, respectively.
    Type: Application
    Filed: September 15, 2023
    Publication date: September 12, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: Ryan Nicholl, David Pain, Andrew Edmonds, Kareemullah Shaik, Edward White
  • Patent number: 12049703
    Abstract: Printhead for a 3D manufacturing system that uses metal electrodeposition to construct parts; embodiments utilize a grid of anodes to achieve high quality parts with features that may be small and detailed. To support grids with thousands or millions of anodes, the printhead may use matrix control with row and column drivers similar to display backplanes. Unlike display backplanes where the design goal is to display images using minimal current, the printhead may be optimized for high current density for fast electrodeposition, and for anode longevity. Current density may exceed 1000 mA per cm-squared, at least an order of magnitude greater than that of display backplanes. Anode longevity may be enhanced by using relatively large anodes compared to the grid pitch of the printhead, by lengthening the conductive paths through anodes, or both. Embodiments may be constructed by adding anode and insulation layers on top of matrix-controlled switching circuits.
    Type: Grant
    Filed: November 23, 2022
    Date of Patent: July 30, 2024
    Assignee: FABRIC8LABS, INC.
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, David Wirth, Kareemullah Shaik
  • Publication number: 20240246299
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Application
    Filed: February 29, 2024
    Publication date: July 25, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman
  • Publication number: 20240229273
    Abstract: Described herein are electrochemical-additive manufacturing (ECAM) systems comprising membranes and methods of operating thereof. An ECAM system comprises an electrode array with individually-addressable electrodes, a deposition electrode, and a membrane positioned between the deposition electrode and electrode array. In some examples, the membrane is configured to transmit protons while blocking gas bubbles, such as oxygen bubbles forming at the electrode array surface. Isolating these bubbles from the deposition electrode helps to preserve the desired component resolution of deposited materials. In some examples, the membrane is also configured to block other components (e.g., metal ions) to maintain different electrolyte compositions (e.g., anolyte and catholyte) on the opposite sides of the membrane. For example, the anolyte may comprise multivalent cations that are oxidized (e.g., Fe+2?Fe+3) thereby decreasing the oxygen gas formation.
    Type: Application
    Filed: February 3, 2023
    Publication date: July 11, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: David Pain, Andrew Edmonds, Glenn Sklar, Kareemullah Shaik
  • Publication number: 20240218546
    Abstract: Described herein are electrochemical-additive manufacturing (ECAM) systems comprising electrophoretically-deposited masks selectively covering a set of individually-addressable electrodes (pixels) in the electrode arrays (printheads). For example, an electrophoretically-deposited mask, comprising one or more patches, can be used to block the electric current through certain array portions thereby preventing electrolytic deposition on the corresponding portions of the deposition electrode during ECAM processes. In some examples, electrode array portions can be masked to cover damaged portions (e.g., stuck-on control circuits, electrically and/or ionically conductive passages in the electrode array) and/or to form special patterns of inactive array portions (that no longer need to be controlled using deposition control circuits). Such electrophoretically-deposited masks can be formed in an ECAM system or an external system. The mask forming can be a single-stage process or a multi-stage process.
    Type: Application
    Filed: June 21, 2023
    Publication date: July 4, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: Sean Stone, Kareemullah Shaik, Shiv Shailendar
  • Publication number: 20240218545
    Abstract: Described herein are methods and systems for additive manufacturing of parts comprising electrolytic deposits and electrophoretic deposits. Such methods and methods provide various new ways for integrating different materials into composite parts. Specifically, an additive manufacturing system comprises an electrode array with individually-addressable electrodes. Each individually-addressable electrode is coupled to a separate deposition control circuit, which selectively connects this electrode to a power supply. When forming a composite part, the electrode array can control the location of each electrolytic deposit (by controlling the current flow through each individually-addressable electrode) and each electrophoretic deposit (by controlling the electric field distribution). An electrolyte solution or an electrophoretic suspension is provided between the electrode array and deposition electrode to form corresponding deposits.
    Type: Application
    Filed: June 27, 2023
    Publication date: July 4, 2024
    Applicant: Fabric8Labs, Inc.
    Inventors: Michael Matthews, David Pain, Sean Stone, Kareemullah Shaik, Charles Nicholas Pateros, Shiv Shailendar
  • Patent number: 12000038
    Abstract: Process for manufacturing a printhead for a 3D manufacturing system that uses metal electrodeposition to construct parts. The printhead may be constructed by depositing layers on top of a backplane that contains control and power circuits. Deposited layers may include insulating layers and an anode layer that contain deposition anodes that are in contact with the electrolyte to drive electrodeposition. Insulating layers may for example be constructed of silicon nitride or silicon dioxide; the anode layer may contain an insoluble conductive material such as platinum group metals and their associated oxides, highly doped semiconducting materials, and carbon based conductors. The anode layer may be deposited using chemical vapor deposition or physical vapor deposition. Alternatively in one or more embodiments the printhead may be constructed by manufacturing a separate anode plane component, and then bonding the anode plane to the backplane.
    Type: Grant
    Filed: July 12, 2022
    Date of Patent: June 4, 2024
    Assignee: FABRIC8LABS, INC.
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, Kareemullah Shaik, Edward White
  • Publication number: 20240162049
    Abstract: A system and method of using electrochemical additive manufacturing to add interconnection features, such as wafer bumps or pillars, or similar structures like heatsinks, to a plate such as a silicon wafer. The plate may be coupled to a cathode, and material for the features may be deposited onto the plate by transmitting current from an anode array through an electrolyte to the cathode. Position actuators and sensors may control the position and orientation of the plate and the anode array to place features in precise positions. Use of electrochemical additive manufacturing may enable construction of features that cannot be created using current photoresist-based methods. For example, pillars may be taller and more closely spaced, with heights of 200 ?m or more, diameters of 10 ?m or below, and inter-pillar spacing below 20 ?m. Features may also extend horizontally instead of only vertically, enabling routing of interconnections to desired locations.
    Type: Application
    Filed: December 7, 2023
    Publication date: May 16, 2024
    Inventors: David Pain, Andrew Edmonds, Jeffrey Herman, Charles Pateros, Kareemullah Shaik
  • Patent number: 11945170
    Abstract: Described herein are electrochemical-additive manufacturing methods and systems using such methods. A method comprises depositing a material onto a deposition electrode by flowing a current between that deposition electrode and each of multiple individually-addressable electrodes, forming an electrode array. These currents are independently controlled based on a target map and using deposition control circuits, each coupled to one individually-addressable electrode. The target map is generated by a system controller based on various characteristics of the system (e.g., the performance of each deposition control circuit and/or individually-addressable electrode, electrolyte composition) and the desired characteristics of the deposited material (e.g., deposition location, uniformity, morphology). Furthermore, when the deposition electrode and the electrode array move relative to each other, the system controller dynamically updates the target map based on their relative positions.
    Type: Grant
    Filed: June 20, 2023
    Date of Patent: April 2, 2024
    Assignee: Fabric8Labs, Inc.
    Inventors: David Pain, Kareemullah Shaik, Joshua Gillespie, Jeffrey Herman