Patents by Inventor Khalil Moussa

Khalil Moussa 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: 20260109864
    Abstract: Compositions and methods for additive manufacturing applications are described herein which, in some embodiments, impart flame resistant and/or flame retardant properties to articles printed or formed from the compositions and methods. In some embodiments, a composition described herein comprises an aluminum-containing species. In some cases, the aluminum-containing species comprises Al(OH)3. In some instances, the aluminum-containing species comprises a species of Formula I or Formula II described herein.
    Type: Application
    Filed: October 20, 2025
    Publication date: April 23, 2026
    Inventors: Khalil MOUSSA, Mehrgan KHAVARI
  • Publication number: 20260078274
    Abstract: In one aspect, build materials for use with a three-dimensional (3D) printing system are described herein. In some embodiments, a build material described herein comprises an acrylate component, a photoinitiator component, a non-curable absorber component, and water. The photoinitiator component of the build material is operable to initiate curing of the acrylate component and/or other curable materials that may optionally be present when the photoinitiator is exposed to incident curing radiation having a Gaussian distribution of wavelengths and a peak wavelength ?. The build material has a penetration depth (Dp) and a critical energy (Ec) at the wavelength ?. In some embodiments, the Dp is greater than 200 ?m and less than 300 ?m, and the Ec is 3-12 mJ/cm2. In other embodiments, the Dp is greater than 10 ?m and less than 50 ?m, and the Ec is 5-40 mJ/cm2.
    Type: Application
    Filed: July 23, 2025
    Publication date: March 19, 2026
    Inventors: Monica KEILSOHN, Michael BRADY, Khalil MOUSSA
  • Patent number: 12421332
    Abstract: Build materials for 3D printing applications are described herein which, in some embodiments, comprise monomeric species operable for producing articles with high Tg and/or high heat deflection temperature while maintaining shelf stability. In one aspect, a polymerizable liquid comprises at least 20 weight percent isocyanurate polyacrylate; a photoinitiator component; and a crystallization inhibitor component comprising monomeric curable material, oligomeric curable material or mixtures thereof, wherein the polymerizable liquid does not exhibit crystallization over a period of 28 days at a storage temperature of 5-10° C.
    Type: Grant
    Filed: June 4, 2024
    Date of Patent: September 23, 2025
    Assignee: 3D Systems, Inc.
    Inventors: Mehrgan Khavari, Khalil Moussa, Scott Broce
  • Patent number: 12420476
    Abstract: Additives for three-dimensional build materials or inks are described herein which, in some embodiments, can impart one or more structural enhancements to articles printed from the build materials. In one aspect, a polymerizable liquid comprises at least one additive including a plurality of cyclopolymerizable functionalities separated by an aliphatic linker or alkylene oxide linker.
    Type: Grant
    Filed: March 8, 2023
    Date of Patent: September 23, 2025
    Assignee: 3D Systems, Inc.
    Inventor: Khalil Moussa
  • Patent number: 12384935
    Abstract: In one aspect, build materials for use with a three-dimensional (3D) printing system are described herein. In some embodiments, a build material described herein comprises an acrylate component, a photoinitiator component, a non-curable absorber component, and water. The photoinitiator component of the build material is operable to initiate curing of the acrylate component and/or other curable materials that may optionally be present when the photoinitiator is exposed to incident curing radiation having a Gaussian distribution of wavelengths and a peak wavelength ?. The build material has a penetration depth (Dp) and a critical energy (Ec) at the wavelength ?. In some embodiments, the Dp is greater than 200 ?m and less than 300 ?m, and the Ec is 3-12 mJ/cm2. In other embodiments, the Dp is greater than 10 ?m and less than 50 ?m, and the Ec is 5-40 mJ/cm2.
    Type: Grant
    Filed: July 13, 2023
    Date of Patent: August 12, 2025
    Assignee: 3D Systems, Inc.
    Inventors: Monica Keilsohn, Michael Brady, Khalil Moussa
  • Publication number: 20250229484
    Abstract: In one aspect, a kit for use in additive manufacturing is provided, the kit comprising a first build material and a second build material, wherein the first build material and the second build material do not have identical chemical compositions, and wherein the first build material and the second build material have at least one property that differs by 10% or less. In another aspect, a method of printing a three-dimensional article is provided, the method comprising providing a first build material and a second build material, and selectively consolidating or solidifying layers of the first build material and layers of the second build material to form the 3D article.
    Type: Application
    Filed: January 17, 2025
    Publication date: July 17, 2025
    Inventor: Khalil MOUSSA
  • Patent number: 12331180
    Abstract: Additives for three-dimensional build materials or inks are described herein which, in some embodiments, can impart flame retardant properties and/or structural enhancements to articles printed from the build materials. In some embodiments, such an additive comprises a compound of Formula I herein, wherein L and Z are ring substituents comprising at least one polymerizable point of unsaturation, and wherein R1 and R2 are independently selected from the group consisting of alkylene and alkenylene, and R3-R6 each represent one to four optional ring substituents, each one of the one to four ring substituents independently selected from the group consisting of alkyl, heteroalkyl, haloalkyl, halo, hydroxyl, alkoxy, amine, amide, and ether, and wherein n is an integer from 1 to 7.
    Type: Grant
    Filed: January 18, 2024
    Date of Patent: June 17, 2025
    Assignee: 3D Systems, Inc.
    Inventor: Khalil Moussa
  • Publication number: 20250162242
    Abstract: Additives for three-dimensional build materials or inks are described herein which, in some embodiments, can impart one or more structural enhancements to articles printed from the build materials. In one aspect, a polymerizable liquid comprises at least one additive including a plurality of cyclopolymerizable functionalities separated by an aliphatic linker or alkylene oxide linker.
    Type: Application
    Filed: December 31, 2024
    Publication date: May 22, 2025
    Inventor: Khalil MOUSSA
  • Patent number: 12269958
    Abstract: In one aspect, inks for use with a three-dimensional (3D) printing system are described herein. In some embodiments, an ink described herein comprises up to 80 wt. % oligomeric curable material; up to 80 wt. % monomeric curable material; up to 10 wt. % photoinitiator; up to 1 wt. % non-curable absorber material; and up to 10 wt. % one or more additional components, based on the total weight of the ink, and wherein the total amount of the foregoing components is equal to 100 wt. %. Additionally, the photoinitiator is operable to initiate curing of the oligomeric curable material and/or the monomeric curable material when the photoinitiator is exposed to incident curing radiation having a peak wavelength ?. Moreover, the ink has a penetration depth (Dp), a critical energy (Ec), and a print through depth (DPT) at the wavelength ? of less than or equal to 2×Dp.
    Type: Grant
    Filed: May 3, 2024
    Date of Patent: April 8, 2025
    Assignee: 3D SYSTEMS, INC.
    Inventor: Khalil Moussa
  • Patent number: 12247094
    Abstract: Polymerizable liquids for 3D printing applications are described herein which, in some embodiments, impart flame resistant and/or flame retardant properties to articles printed from the build materials. The polymerizable liquids may also impart desirable mechanical properties to the articles. In some embodiments, a polymerizable liquid comprises a curable isocyanurate component in an amount of at least 20 wt. %, based on total weight of the polymerizable liquid, and an organophosphate component comprises one or more organophosphate compounds. In some embodiments, the polymerizable liquid further comprises an acrylate component.
    Type: Grant
    Filed: January 10, 2024
    Date of Patent: March 11, 2025
    Assignee: 3D SYSTEMS, INC.
    Inventor: Khalil Moussa
  • Publication number: 20250059378
    Abstract: Polymerizable liquids for 3D printing applications are described herein which, in some embodiments, impart flame resistant and/or flame retardant properties to articles printed from the liquids. The polymerizable liquids may also impart desirable mechanical properties to the articles. In some embodiments, a polymerizable liquid comprises a curable isocyanurate component in an amount of at least 5 wt. %, based on total weight of the polymerizable liquid, and a brominated acrylate ester component. Additionally, methods of printing three-dimensional articles using said polymerizable liquids are described herein.
    Type: Application
    Filed: November 4, 2024
    Publication date: February 20, 2025
    Inventor: Khalil MOUSSA
  • Patent number: 12220861
    Abstract: Additives for three-dimensional build materials or inks are described herein which, in some embodiments, can impart one or more structural enhancements to articles printed from the build materials. In one aspect, a polymerizable liquid comprises at least one additive including a plurality of cyclopolymerizable functionalities separated by an aliphatic linker or alkylene oxide linker.
    Type: Grant
    Filed: December 20, 2023
    Date of Patent: February 11, 2025
    Assignee: 3D SYSTEMS, INC.
    Inventor: Khalil Moussa
  • Patent number: 12168735
    Abstract: Polymerizable liquids for 3D printing applications are described herein which, in some embodiments, impart flame resistant and/or flame retardant properties to articles printed from the liquids. The polymerizable liquids may also impart desirable mechanical properties to the articles. In some embodiments, a polymerizable liquid comprises a curable isocyanurate component in an amount of at least 5 wt. %, based on total weight of the polymerizable liquid, and a brominated acrylate ester component. Additionally, methods of printing three-dimensional articles using said polymerizable liquids are described herein.
    Type: Grant
    Filed: March 9, 2022
    Date of Patent: December 17, 2024
    Assignee: 3D SYSTEMS, INC.
    Inventor: Khalil Moussa
  • Publication number: 20240368418
    Abstract: In one aspect, inks for use with a three-dimensional (3D) printing system are described herein. In some embodiments, an ink described herein comprises up to 80 wt. % oligomeric curable material; up to 80 wt. % monomeric curable material; up to 10 wt. % photoinitiator; up to 1 wt. % non-curable absorber material; and up to 10 wt. % one or more additional components, based on the total weight of the ink, and wherein the total amount of the foregoing components is equal to 100 wt. %. Additionally, the photoinitiator is operable to initiate curing of the oligomeric curable material and/or the monomeric curable material when the photoinitiator is exposed to incident curing radiation having a peak wavelength ?. Moreover, the ink has a penetration depth (Dp), a critical energy (Ec), and a print through depth (DPT) at the wavelength ? of less than or equal to 2×Dp.
    Type: Application
    Filed: May 3, 2024
    Publication date: November 7, 2024
    Inventor: Khalil MOUSSA
  • Publication number: 20240317909
    Abstract: build materials for 3D printing applications are described herein which, in some embodiments, comprise monomeric species operable for producing articles with high Tg and/or high heat deflection temperature while maintaining shelf stability. In one aspect, a polymerizable liquid comprises at least 20 weight percent isocyanurate polyacrylate; a photoinitiator component; and a crystallization inhibitor component comprising monomeric curable material, oligomeric curable material or mixtures thereof, wherein the polymerizable liquid does not exhibit crystallization over a period of 28 days at a storage temperature of 5-10° C.
    Type: Application
    Filed: June 4, 2024
    Publication date: September 26, 2024
    Inventors: Mehrgan KHAVARI, Khalil MOUSSA, Scott BROCE
  • Patent number: 12030968
    Abstract: Build materials for 3D printing applications are described herein which, in some embodiments, comprise monomeric species operable for producing articles with high Tg and/or high heat deflection temperature while maintaining shelf stability. In one aspect, a polymerizable liquid comprises at least 20 weight percent isocyanurate polyacrylate; a photoinitiator component; and a crystallization inhibitor component comprising monomeric curable material, oligomeric curable material or mixtures thereof, wherein the polymerizable liquid does not exhibit crystallization over a period of 28 days at a storage temperature of 5-10° C.
    Type: Grant
    Filed: January 13, 2023
    Date of Patent: July 9, 2024
    Assignee: 3D SYSTEMS, INC.
    Inventors: Mehrgan Khavari, Khalil Moussa, Scott Broce
  • Patent number: 12018165
    Abstract: In one aspect, inks for use with a three-dimensional (3D) printing system are described herein. In some embodiments, an ink described herein comprises up to 80 wt. % oligomeric curable material; up to 80 wt. % monomeric curable material; up to 10 wt. % photoinitiator; up to 1 wt. % non-curable absorber material; and up to 10 wt. % one or more additional components, based on the total weight of the ink, and wherein the total amount of the foregoing components is equal to 100 wt. %. Additionally, the photoinitiator is operable to initiate curing of the oligomeric curable material and/or the monomeric curable material when the photoinitiator is exposed to incident curing radiation having a peak wavelength ?. Moreover, the ink has a penetration depth (Dp), a critical energy (Ec), and a print through depth (DPT) at the wavelength ? of less than or equal to 2×Dp.
    Type: Grant
    Filed: May 31, 2023
    Date of Patent: June 25, 2024
    Inventor: Khalil Moussa
  • Publication number: 20240191089
    Abstract: In one aspect, inks for use with a three-dimensional (3D) printing system are described herein. In some embodiments, a composite ink described herein comprises a carrier ink comprising a curable material and a solid powder filler dispersed in the carrier ink. In some cases, the composite ink, in an uncured state, has a highly accelerated life testing (HALT) score of at least 2 when tested at 65° C. for at least 14 days. Additionally, in some embodiments, the composite ink, in an uncured state, has an average loss factor tan ? of less than or equal to 3 or less than or equal to 2 over an angular frequency range of 0.5 to 5 rad/s.
    Type: Application
    Filed: December 7, 2023
    Publication date: June 13, 2024
    Inventors: Mehrgan KHAVARI, Khalil MOUSSA
  • Publication number: 20240174781
    Abstract: Polymerizable liquids for 3D printing applications are described herein which, in some embodiments, impart flame resistant and/or flame retardant properties to articles printed from the build materials. The polymerizable liquids may also impart desirable mechanical properties to the articles. In some embodiments, a polymerizable liquid comprises a curable isocyanurate component in an amount of at least 20 wt. %, based on total weight of the polymerizable liquid, and an organophosphate component comprises one or more organophosphate compounds. In some embodiments, the polymerizable liquid further comprises an acrylate component.
    Type: Application
    Filed: January 10, 2024
    Publication date: May 30, 2024
    Inventor: Khalil MOUSSA
  • Publication number: 20240158610
    Abstract: Additives for three-dimensional build materials or inks are described herein which, in some embodiments, can impart flame retardant properties and/or structural enhancements to articles printed from the build materials. In some embodiments, such an additive comprises a compound of Formula I herein, wherein L and Z are ring substituents comprising at least one polymerizable point of unsaturation, and wherein R1 and R2 are independently selected from the group consisting of alkylene and alkenylene, and R3-R6 each represent one to four optional ring substituents, each one of the one to four ring substituents independently selected from the group consisting of alkyl, heteroalkyl, haloalkyl, halo, hydroxyl, alkoxy, amine, amide, and ether, and wherein n is an integer from 1 to 7.
    Type: Application
    Filed: January 18, 2024
    Publication date: May 16, 2024
    Inventor: Khalil MOUSSA