Patents by Inventor Paul J. Leavitt

Paul J. Leavitt 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).

  • Additive manufacturing system with extended printing volume, and methods of use thereof
    Patent number: 10549517
    Abstract: An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.
    Type: Grant
    Filed: April 28, 2017
    Date of Patent: February 4, 2020
    Assignee: STRATASYS, INC.
    Inventors: S. Scott Crump, Dominic F. Mannella, William J. Swanson, Kevin C. Johnson, Ronald G. Schloesser, Joseph E. LaBossiere, Richard Thomas Anderson, Michael D. Bosveld, Paul J. Leavitt
  • Ripple reduction in an additive manufacturing system
    Patent number: 10513103
    Abstract: An assembly for use in an additive manufacturing system to print a three-dimensional part that includes an extruder comprising a gear and a motor that turns the gear, wherein rotation of the gear regulates a flow of material out of the extruder. A controller, provides a control signal to the motor to control the rate at which the motor turns the at least one gear and incorporates a time-varying signal into the control signal to reduce ripples in the material output by the extruder.
    Type: Grant
    Filed: July 21, 2015
    Date of Patent: December 24, 2019
    Assignee: STRATASYS, INC.
    Inventors: Paul J. Leavitt, Andrew Rice, Timothy Hjelsand
  • Additive manufacturing systems and method of filling voids in 3D parts
    Patent number: 10471702
    Abstract: A method of additive three-dimensional object production includes depositing liquefied material to produce two roads and placing an extruder tip having a bottom surface that surrounds an orifice such that one portion of the bottom surface is sealed against one of the two roads and another part of the bottom surface is sealed against the other of the two roads and the orifice is positioned over a space between the two roads. Liquefied material is then extruded through the orifice to fill the space between the two roads.
    Type: Grant
    Filed: December 12, 2016
    Date of Patent: November 12, 2019
    Assignee: STRATASYS, INC.
    Inventors: Paul J. Leavitt, J. Samuel Batchelder
  • ADDITIVE MANUFACTURING SYSTEM WITH EXTENDED PRINTING VOLUME, AND METHODS OF USE THEREOF
    Publication number: 20170232685
    Abstract: An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.
    Type: Application
    Filed: April 28, 2017
    Publication date: August 17, 2017
    Inventors: S. Scott Crump, Dominic F. Mannella, William J. Swanson, Kevin C. Johnson, Ronald G. Schloesser, Joseph E. LaBossiere, Richard Thomas Anderson, Michael D. Bosveld, Paul J. Leavitt
  • RIPPLE REDUCTION IN AN ADDITIVE MANUFACTURING SYSTEM
    Publication number: 20170203507
    Abstract: An assembly for use in an additive manufacturing system to print a three-dimensional part that includes an extruder comprising a gear and a motor that turns the gear, wherein rotation of the gear regulates a flow of material out of the extruder. A controller, provides a control signal to the motor to control the rate at which the motor turns the at least one gear and incorporates a time-varying signal into the control signal to reduce ripples in the material output by the extruder.
    Type: Application
    Filed: July 21, 2015
    Publication date: July 20, 2017
    Inventors: Paul J. Leavitt, Andrew Rice, Timothy Hjilsand
  • ADDITIVE MANUFACTURING SYSTEMS AND METHOD OF FILLING VOIDS IN 3D PARTS
    Publication number: 20170165920
    Abstract: A method of additive three-dimensional object production includes depositing liquefied material to produce two roads and placing an extruder tip having a bottom surface that surrounds an orifice such that one portion of the bottom surface is sealed against one of the two roads and another part of the bottom surface is sealed against the other of the two roads and the orifice is positioned over a space between the two roads. Liquefied material is then extruded through the orifice to fill the space between the two roads.
    Type: Application
    Filed: December 12, 2016
    Publication date: June 15, 2017
    Inventors: Paul J. Leavitt, J. Samuel Batchelder
  • Additive manufacturing system with extended printing volume, and methods of use thereof
    Patent number: 9636868
    Abstract: An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.
    Type: Grant
    Filed: August 15, 2013
    Date of Patent: May 2, 2017
    Assignee: Stratasys, Inc.
    Inventors: S. Scott Crump, Dominic F. Mannella, William J. Swanson, Kevin C. Johnson, Ronald G. Schloesser, Joseph E. LaBossiere, Richard Thomas Anderson, Michael D. Bosveld, Paul J. Leavitt
  • Filament drive mechanism for use in additive manufacturing system
    Patent number: 9321609
    Abstract: A filament drive mechanism for use with an additive manufacturing system, the filament drive mechanism comprising first and second drive shafts engaged with each other and configured to rotate in opposing rotational directions around substantially parallel and fixed axes, where the first and second drive shafts include engagement surfaces substantially aligned with each other for engaging a filament therebetween.
    Type: Grant
    Filed: December 7, 2012
    Date of Patent: April 26, 2016
    Assignee: Stratasys, Inc.
    Inventors: Shawn M. Koop, Peter D. Schuller, Paul J. Leavitt
  • Liquefier assembly for use in additive manufacturing system
    Patent number: 9233506
    Abstract: A liquefier assembly for use in an additive manufacturing system, where the liquefier assembly includes a liquefier tube, a nozzle secured to an outlet end of the liquefier tube, a heating element extending at least partially around the liquefier tube to generate a hot zone in the liquefier tube, a hollow spacer disposed in the channel; and a hollow liner disposed in the channel abutting against an upstream shoulder of the hollow spacer.
    Type: Grant
    Filed: December 7, 2012
    Date of Patent: January 12, 2016
    Assignee: Stratasys, Inc.
    Inventor: Paul J. Leavitt
  • Automated calibration method for additive manufacturing system, and method of use thereof
    Patent number: 9205690
    Abstract: A method for calibrating a print head for use in an additive manufacturing system, the method comprising positioning the print head over a calibration target, where the calibration target has a top surface with a plurality of edges. The method further comprising moving a tip of the print head to identify coordinate locations of the edges, and setting a calibration parameter for the print head.
    Type: Grant
    Filed: March 16, 2012
    Date of Patent: December 8, 2015
    Assignee: Stratasys, Inc.
    Inventors: Paul J. Leavitt, Paul H. Fuchs, J. Samuel Batchelder
  • LIQUEFIER ASSEMBLY FOR USE IN ADDITIVE MANUFACTURING SYSTEM
    Publication number: 20140159284
    Abstract: A liquefier assembly for use in an additive manufacturing system, where the liquefier assembly includes a liquefier tube, a nozzle secured to an outlet end of the liquefier tube, a heating element extending at least partially around the liquefier tube to generate a hot zone in the liquefier tube, a hollow spacer disposed in the channel; and a hollow liner disposed in the channel abutting against an upstream shoulder of the hollow spacer.
    Type: Application
    Filed: December 7, 2012
    Publication date: June 12, 2014
    Applicant: STRATASYS, INC.
    Inventor: Paul J. Leavitt
  • FILAMENT DRIVE MECHANISM FOR USE IN ADDITIVE MANUFACTURING SYSTEM
    Publication number: 20140159273
    Abstract: A filament drive mechanism for use with an additive manufacturing system, the filament drive mechanism comprising first and second drive shafts engaged with each other and configured to rotate in opposing rotational directions around substantially parallel and fixed axes, where the first and second drive shafts include engagement surfaces substantially aligned with each other for engaging a filament therebetween.
    Type: Application
    Filed: December 7, 2012
    Publication date: June 12, 2014
    Applicant: Stratasys, Inc.
    Inventors: Shawn M. Koop, Peter D. Schuller, Paul J. Leavitt
  • ADDITIVE MANUFACTURING SYSTEM WITH EXTENDED PRINTING VOLUME, AND METHODS OF USE THEREOF
    Publication number: 20140048981
    Abstract: An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.
    Type: Application
    Filed: August 15, 2013
    Publication date: February 20, 2014
    Applicant: Stratasys, Inc.
    Inventors: S. Scott Crump, Dominic F. Mannella, William J. Swanson, Kevin C. Johnson, Ronald G. Schloesser, Joseph E. LaBossiere, Richard Thomas Anderson, Michael D. Bosveld, Paul J. Leavitt
  • AUTOMATED CALIBRATION METHOD FOR ADDITIVE MANUFACTURING SYSTEM, AND METHOD OF USE THEREOF
    Publication number: 20130242317
    Abstract: A method for calibrating a print head for use in an additive manufacturing system, the method comprising positioning the print head over a calibration target, where the calibration target has a top surface with a plurality of edges. The method further comprising moving a tip of the print head to identify coordinate locations of the edges, and setting a calibration parameter for the print head.
    Type: Application
    Filed: March 16, 2012
    Publication date: September 19, 2013
    Applicant: STRATASYS, INC.
    Inventors: Paul J. Leavitt, Paul H. Fuchs, J. Samuel Batchelder
  • Extrusion head for use in extrusion-based layered deposition modeling
    Patent number: 7625200
    Abstract: An extrusion head comprising at least one mounting structure, a first liquefier pump secured to the at least one mounting structure, a second liquefier pump disposed adjacent to the first liquefier pump, a toggle mechanism supported by the at least one mounting structure and configured to move the second liquefier pump relative to the first liquefier pump along a first axis, and a slot engagement assembly connected in part to the second liquefier pump for defining a range of motion for the second liquefier pump along the first axis.
    Type: Grant
    Filed: July 31, 2007
    Date of Patent: December 1, 2009
    Assignee: Stratasys, Inc.
    Inventor: Paul J. Leavitt
  • Extrusion head for use in extrusion-based layered deposition modeling
    Publication number: 20090035405
    Abstract: An extrusion head comprising at least one mounting structure, a first liquefier pump secured to the at least one mounting structure, a second liquefier pump disposed adjacent to the first liquefier pump, a toggle mechanism supported by the at least one mounting structure and configured to move the second liquefier pump relative to the first liquefier pump along a first axis, and a slot engagement assembly connected in part to the second liquefier pump for defining a range of motion for the second liquefier pump along the first axis.
    Type: Application
    Filed: July 31, 2007
    Publication date: February 5, 2009
    Applicant: Stratasys, Inc.
    Inventor: Paul J. Leavitt
  • High-temperature modeling method
    Patent number: 7297304
    Abstract: A method for three-dimensional modeling builds up three-dimensional objects in a heated build chamber by dispensing modeling material from a dispensing head onto a base in a predetermined pattern. Physical and thermal separation are maintained between the heated build chamber and motion control components that control the motion of the dispensing head and the base. Thermal isolation of the motion control components from the build chamber allows the chamber to be maintained at a high temperature, and has other practical advantages as well.
    Type: Grant
    Filed: November 26, 2003
    Date of Patent: November 20, 2007
    Assignee: Stratasys, Inc.
    Inventors: William J. Swanson, Patrick W. Turley, Paul J. Leavitt, Peter J. Karwoski, Joseph E. LaBossiere, Robert L. Skubic
  • High-precision modeling filament
    Patent number: 7122246
    Abstract: Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.
    Type: Grant
    Filed: February 2, 2005
    Date of Patent: October 17, 2006
    Assignee: Stratasys, Inc.
    Inventors: James W. Comb, William R. Priedeman, Jr., Paul J. Leavitt, Robert L. Skubic, John Samuel Batchelder
  • High-precision modeling filament
    Patent number: 6866807
    Abstract: Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.
    Type: Grant
    Filed: April 17, 2002
    Date of Patent: March 15, 2005
    Assignee: Stratasys, Inc.
    Inventors: James W. Comb, William R. Priedeman, Jr., Paul J. Leavitt, Robert L. Skubic, John Samuel Batchelder
  • High-Temperature modeling method
    Publication number: 20040104515
    Abstract: A method for three-dimensional modeling builds up three-dimensional objects in a heated build chamber by dispensing modeling material from a dispensing head onto a base in a predetermined pattern. Physical and thermal separation are maintained between the heated build chamber and motion control components that control the motion of the dispensing head and the base. Thermal isolation of the motion control components from the build chamber allows the chamber to be maintained at a high temperature, and has other practical advantages as well.
    Type: Application
    Filed: November 26, 2003
    Publication date: June 3, 2004
    Applicant: Stratasys, Inc.
    Inventors: William J. Swanson, Patrick W. Turley, Paul J. Leavitt, Peter J. Karwoski, Joseph E. LaBossiere, Robert L. Skubic