Patents by Inventor Muhammad Faizan ZAFAR
Muhammad Faizan ZAFAR 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).
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Patent number: 11872689Abstract: One aspect is an apparatus including an additively manufactured component including a surface with an end effector feature, the end effector feature co-additively manufactured with the additively manufactured component and configured to be gripped by a corresponding end effector on a robot. In an aspect, the end effector feature includes a recess in the surface. In another aspect, the recess includes an angled face. In an aspect, the recess has a teardrop shape. An aspect further includes an identification feature. In an aspect, the end effector feature includes a plurality of recesses in the surface. In another aspect, the end effector feature enables a 3-point kinematic self-aligning positive control lock.Type: GrantFiled: March 19, 2018Date of Patent: January 16, 2024Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Oussama Rawas, Roy Smith, Alex James Hamade, Muhammad Faizan Zafar, Keith Allen Fleming, Eahab Nagi El Naga, Antonio Bernerd Martinez, Chukwubuikem Marcel Okoli
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Patent number: 11806941Abstract: Part retention features are disclosed for securing additively manufactured (AM) parts or for securing an AM part with another component, such as a node, panel, tube, extrusion, and the like, while an adhesive is being applied and/or while the adhesive is undergoing expansion due to a subsequent curing process. The retention features described herein can be used in the context of one or more AM parts such that the elements used to house the retention features (e.g., grooves, apertures, elastic elements, etc.) can advantageously be co-printed with the AM part, thereby removing a manufacturing step. The retention features also can be made with flatter profiles than existing solutions, making the overall structure smaller and less cumbersome to assemble.Type: GrantFiled: August 21, 2020Date of Patent: November 7, 2023Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Chukwubuikem Marcel Okoli, David Brian TenHouten, Muhammad Faizan Zafar, Antonio Bernerd Martinez, Lukas Philip Czinger
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Patent number: 11786971Abstract: A high precision Interface Node is disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. The Interface Node may connect with another component or a Linking Node. The Interface Node is manufactured to achieve high precision functionality while enabling volume production. Current additive manufacturing technologies allow for the printing of high precision features to be manufactured, but generally this is performed at a slower rate. Consequently, in one aspect, the size of the Interface Nodes is reduced in order to overcome at least part of the slower production volume caused by creating the high precision Interface Nodes. The components and Linking Nodes to which the Interface Node is connected may only have basic features and functions. Accordingly, this latter category of components may use a high print rate and thus high production volume.Type: GrantFiled: November 10, 2017Date of Patent: October 17, 2023Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Kevin Robert Czinger, Broc William TenHouten, Antonio Bernerd Martinez, Steven Blair Massey, Jr., Narender Shankar Lakshman, William David Kreig, Jon Paul Gunner, David Brian TenHouten, Eahab Nagi El Naga, Muhammad Faizan Zafar
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Patent number: 11773956Abstract: Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.Type: GrantFiled: December 10, 2020Date of Patent: October 3, 2023Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Antonio Bernerd Martinez, Eahab Nagi El Naga, David Brian TenHouten, John Russell Bucknell, Broc William TenHouten, Chukwubuikem Mercel Okoli, Thomas Samuel Bowden, Jr., Muhammad Faizan Zafar
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Patent number: 11613078Abstract: Apparatus and methods for additively manufacturing adhesive inlet and outlet ports are presented herein. Adhesive inlet and outlet ports are additively manufactured to include additively manufactured (AM) valves for reducing and/or eliminating sealant leakage and backflow. Robot end effectors are tailored to interface with the AM inlet and outlet ports and to provide an adhesive source and/or a vacuum source. AM inlet and outlet ports enable robust, lightweight, multi-material AM parts connected via adhesive joining.Type: GrantFiled: April 20, 2018Date of Patent: March 28, 2023Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Antonio Bernerd Martinez, Muhammad Faizan Zafar, Chukwubuikem Marcel Okoli, William David Kreig, Roy Smith, David Brian TenHouten
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Patent number: 11433557Abstract: A buffer block apparatus for securing a node may be described. The buffer block apparatus may include a first surface having disposed thereon at least one first zero-point feature configured for a first zero-point interface with a robotic assembly apparatus; and a second surface, different from the first surface, configured to connect with a first surface of a node and form a first rigid connection between the buffer block apparatus and the node, wherein the buffer block apparatus provides at least one reference coordinate system with respect to the node.Type: GrantFiled: August 27, 2019Date of Patent: September 6, 2022Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Eahab Nagi El Naga, Keith Allen Fleming, Matthew Cooper Keller, Lukas Philip Czinger, Chukwubuikem Marcel Okoli, Michael Thomas Kenworthy, Matthew Coleman Tindall, Justin David Almeleh, Matthew Michael O'Brien, Broc William TenHouten, Oussama Rawas, Juan Cuauhtemoc Munoz, Muhammad Faizan Zafar, Jamison Van Bruch, Thomas Samuel Bowden, Jr., Alex James Hamade
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Patent number: 11420262Abstract: Systems and methods for co-casting of additively manufactured, high precision Interface Nodes are disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. Co-casting of Interface Nodes by casting a part onto the Interface Node results in a hybrid structure comprising the cast part and the additively manufactured Interface Node. The interface node may include at least one of a node-to-tube connection, node-to-panel connection, or a node-to-extrusion connection. In an embodiment, engineered surfaces may be provided on the Interface Node to improve the blend between the Interface Node and the cast part during the co-casting process.Type: GrantFiled: January 31, 2018Date of Patent: August 23, 2022Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Narender Shankar Lakshman, Broc William TenHouten, Kevin Robert Czinger, Antonio Bernerd Martinez, Jon Paul Gunner, Muhammad Faizan Zafar
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Publication number: 20220194488Abstract: An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a channel, etc., for accepting another structure, e.g., a tube, a panel, etc. The node can include a node surface of a receptacle extending into the node. The receptacle can receive a structure, and a seal interface on the node surface can seat a seal member between the node surface and the structure to create an adhesive region between the node and the structure, the adhesive region being bounded by the node surface, the structure, and the seal member. The node can also include two channels connecting an exterior surface of the node to the adhesive region. In this way, adhesive can be injected into the adhesive region between the node and the structure, and the adhesive can be contained by the seal member.Type: ApplicationFiled: December 1, 2021Publication date: June 23, 2022Inventors: Chukwubuikem Marcel OKOLI, David Brian Tenhouten, Antonio Bernerd Martinez, Muhammad Faizan Zafar, William David Kreig, Kevin Robert Czinger, Broc William Tenhouten
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Publication number: 20220176450Abstract: Techniques for optimizing powder hole removal are disclosed. In one aspect, an apparatus for inserting powder removal features may identify what powder removal features are optimal for a given AM component, as well as the optimal location and physical characteristics of these features. The features are automatedly added to the component, and an FEA test is run. In the event of failure, the offending feature is removed and the process is repeated. If successful then the loose powder may be removed in a post-processing step following AM.Type: ApplicationFiled: February 25, 2022Publication date: June 9, 2022Inventors: Narender Shankar Lakshman, Thomas Samuel BOWDEN, JR., John Russell BUCKNELL, Ross Harrison BYERS, Broc William TenHOUTEN, Antonio Bernerd MARTINEZ, Muhammad Faizan ZAFAR, Richard Winston HOYLE, Chukwubuikem Marcel OKOLI
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Patent number: 11292058Abstract: Techniques for optimizing powder hole removal are disclosed. In one aspect, an apparatus for inserting powder removal features may identify what powder removal features are optimal for a given AM component, as well as the optimal location and physical characteristics of these features. The features are automatedly added to the component, and an FEA test is run. In the event of failure, the offending feature is removed and the process is repeated. If successful then the loose powder may be removed in a post-processing step following AM.Type: GrantFiled: September 12, 2017Date of Patent: April 5, 2022Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Narender Shankar Lakshman, Thomas Samuel Bowden, Jr., John Russell Bucknell, Ross Harrison Byers, Broc William TenHouten, Antonio Bernerd Martinez, Muhammad Faizan Zafar, Richard Winston Hoyle, Chukwubuikem Marcel Okoli
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Publication number: 20220081045Abstract: An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a channel, etc., for accepting another structure, e.g., a tube, a panel, etc. The node can include a node surface of a receptacle extending into the node. The receptacle can receive a structure, and a seal interface on the node surface can seat a seal member between the node surface and the structure to create an adhesive region between the node and the structure, the adhesive region being bounded by the node surface, the structure, and the seal member. The node can also include two channels connecting an exterior surface of the node to the adhesive region. In this way, adhesive can be injected into the adhesive region between the node and the structure, and the adhesive can be contained by the seal member.Type: ApplicationFiled: November 29, 2021Publication date: March 17, 2022Inventors: Chukwubuikem Marcel OKOLI, David Brian TENHOUTEN, Antonio Bernerd MARTINEZ, Muhammad Faizan ZAFAR, William David KREIG, Kevin Robert CZINGER, Broc William TENHOUTEN
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Publication number: 20220055317Abstract: Part retention features are disclosed for securing additively manufactured (AM) parts or for securing an AM part with another component, such as a node, panel, tube, extrusion, and the like, while an adhesive is being applied and/or while the adhesive is undergoing expansion due to a subsequent curing process. The retention features described herein can be used in the context of one or more AM parts such that the elements used to house the retention features (e.g., grooves, apertures, elastic elements, etc.) can advantageously be co-printed with the AM part, thereby removing a manufacturing step. The retention features also can be made with flatter profiles than existing solutions, making the overall structure smaller and less cumbersome to assemble.Type: ApplicationFiled: August 21, 2020Publication date: February 24, 2022Inventors: Chukwubuikem Marcel Okoli, David Brian TenHouten, Muhammad Faizan Zafar, Antonio Bernerd Martinez, Lukas Philip Czinger
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Patent number: 11214317Abstract: An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a channel, etc., for accepting another structure, e.g., a tube, a panel, etc. The node can include a node surface of a receptacle extending into the node. The receptacle can receive a structure, and a seal interface on the node surface can seat a seal member between the node surface and the structure to create an adhesive region between the node and the structure, the adhesive region being bounded by the node surface, the structure, and the seal member. The node can also include two channels connecting an exterior surface of the node to the adhesive region. In this way, adhesive can be injected into the adhesive region between the node and the structure, and the adhesive can be contained by the seal member.Type: GrantFiled: April 24, 2018Date of Patent: January 4, 2022Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: Chukwubuikem Marcel Okoli, David Brian TenHouten, Antonio Bernerd Martinez, Muhammad Faizan Zafar, William David Kreig, Kevin Robert Czinger, Broc William TenHouten
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Patent number: 11118387Abstract: The present disclosure is directed to a door hinge mechanism for a vehicle. The door hinge mechanism may include a door configured to open and close relative to the frame, and a hinge secured to an interior of the door and an exterior of the frame. The hinge may be configured to open the door by sliding the door away from the frame and pivoting the door relative to the frame.Type: GrantFiled: October 20, 2016Date of Patent: September 14, 2021Assignee: Faraday & Future Inc.Inventors: Umran Ashraf, Muhammad Faizan Zafar, John Michael Colt
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Publication number: 20210148449Abstract: Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.Type: ApplicationFiled: December 10, 2020Publication date: May 20, 2021Inventors: Antonio Bernerd Martinez, Eahab Nagi El Naga, David Brian TenHouten, John Russell Bucknell, Broc William TenHouten, Chukwubuikem Mercel Okoli, Thomas Samuel Bowden, JR., Muhammad Faizan Zafar
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Patent number: 10895315Abstract: Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.Type: GrantFiled: July 7, 2017Date of Patent: January 19, 2021Assignee: Divergent Technologies, Inc.Inventors: Antonio Bernerd Martinez, Eahab Nagi El Naga, David Brian TenHouten, John Russell Bucknell, Broc William TenHouten, Chukwubuikem Marcel Okoli, Thomas Samuel Bowden, Jr., Muhammad Faizan Zafar
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Publication number: 20200070365Abstract: A buffer block apparatus for securing a node may be described. The buffer block apparatus may include a first surface having disposed thereon at least one first zero-point feature configured for a first zero-point interface with a robotic assembly apparatus; and a second surface, different from the first surface, configured to connect with a first surface of a node and form a first rigid connection between the buffer block apparatus and the node, wherein the buffer block apparatus provides at least one reference coordinate system with respect to the node.Type: ApplicationFiled: August 27, 2019Publication date: March 5, 2020Inventors: Eahab Nagi El Naga, Keith Allen Fleming, Matthew Cooper Keller, Lukas Philip Czinger, Chukwubuikem Marcel Okoli, Michael Thomas Kenworthy, Matthew Coleman Tindall, Justin David Almeleh, Matthew Michael O'Brien, Broc William TenHouten, Oussama Rawas, Juan Cuauhtemoc Munoz, Muhammad Faizan Zafar, Jamison Van Bruch, Thomas Samuel Bowden, JR., Alex James Hamade
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Publication number: 20190351642Abstract: A self-supporting lattice structure is provided with high strength-to-weight ratios. In an aspect, an additively manufactured structure is provided that includes a self-supporting lattice structure formed by a plurality of unit cells. Moreover, each unit cell includes a symmetrical frame with voids or cutouts extending through each of the side surfaces of the symmetrical frame to define a negative space therein. The negative space substantially reduces the density and overall weight of the self-supporting lattice structure.Type: ApplicationFiled: May 15, 2018Publication date: November 21, 2019Inventor: Muhammad Faizan Zafar
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Publication number: 20190322055Abstract: An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a channel, etc., for accepting another structure, e.g., a tube, a panel, etc. The node can include a node surface of a receptacle extending into the node. The receptacle can receive a structure, and a seal interface on the node surface can seat a seal member between the node surface and the structure to create an adhesive region between the node and the structure, the adhesive region being bounded by the node surface, the structure, and the seal member. The node can also include two channels connecting an exterior surface of the node to the adhesive region. In this way, adhesive can be injected into the adhesive region between the node and the structure, and the adhesive can be contained by the seal member.Type: ApplicationFiled: April 24, 2018Publication date: October 24, 2019Inventors: Chukwubuikem Marcel Okoli, David Brian TenHouten, Antonio Bernerd Martinez, Muhammad Faizan Zafar, William David Kreig, Kevin Robert Czinger, Broc William TenHouten
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Publication number: 20190322040Abstract: Apparatus and methods for additively manufacturing adhesive inlet and outlet ports are presented herein. Adhesive inlet and outlet ports are additively manufactured to include additively manufactured (AM) valves for reducing and/or eliminating sealant leakage and backflow. Robot end effectors are tailored to interface with the AM inlet and outlet ports and to provide an adhesive source and/or a vacuum source. AM inlet and outlet ports enable robust, lightweight, multi-material AM parts connected via adhesive joining.Type: ApplicationFiled: April 20, 2018Publication date: October 24, 2019Inventors: Antonio Bernerd Martinez, JR., Muhammad Faizan Zafar, Chukwubuikem Marcel Okoli, William David Kreig, Roy Smith, David Brian TenHOUTEN