Patents by Inventor Ricardo Fulop

Ricardo Fulop 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: 20210346962
    Abstract: The devices, systems, and methods of the present disclosure are directed to spreader positioning techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, an additive manufacturing system may include a roller and a print carriage. In a layer-by-layer fabrication process, the roller may move in advance of the print carriage over a dimension of a volume to spread a respective layer of powder onto which the print carriage delivers a binder. Controlling the position of the roller may facilitate achieving consistent layer characteristics which, in turn, may facilitate fabrication of high quality parts.
    Type: Application
    Filed: April 20, 2018
    Publication date: November 11, 2021
    Applicant: Desktop Metal, Inc.
    Inventors: Jonah Myerberg, Ricardo Fulop, Richard Fontana, Charles Edward Martin, Brett Schuster, Emanuel Michael Sachs
  • Publication number: 20210283688
    Abstract: Techniques and compositions are disclosed for three-dimensional printing with powder/binder systems including, but not limited to, metal injection molding powder materials, highly-filled polymer composites, and any other materials suitable for handling with various additive manufacturing techniques, and further suitable for subsequent debinding and thermal processing into a final object.
    Type: Application
    Filed: December 14, 2017
    Publication date: September 16, 2021
    Applicant: Desktop Metal, Inc.
    Inventors: Ricardo Fulop, Animesh Bose, Michael Andrew Gibson, Richard Remo Fontana, Jonah Samuel Myerberg
  • Publication number: 20210283693
    Abstract: The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.
    Type: Application
    Filed: April 20, 2018
    Publication date: September 16, 2021
    Applicant: Desktop Metal, Inc.
    Inventors: Jonah Myerberg, Ricardo Fulop, Brett Schuster, Emanuel Michael Sachs, Paul A. Hoisington, Anastasios John Hart, Keith Vaillancourt, Steven Garrant, George Hudelson
  • Publication number: 20210260654
    Abstract: Techniques for debinding additively fabricated parts are described that do not require solvent debinding or catalytic debinding, and that may be performed using only thermal debinding in a furnace. As a result, in at least some cases debinding and sintering may take place sequentially within a single furnace. In some embodiments, the techniques may utilize particular materials as binders that allow for a thermal debinding process that does not negatively affect the parts.
    Type: Application
    Filed: January 26, 2021
    Publication date: August 26, 2021
    Applicant: Desktop Metal, Inc.
    Inventors: John Reidy, Nihan Tuncer, Animesh Bose, Christopher Craven, Alexander C. Barbati, Ricardo Fulop, Karl-Heinz Schofalvi
  • Publication number: 20210147665
    Abstract: Techniques for debinding additively fabricated parts are described that do not require solvent debinding or catalytic debinding, and that may be performed using only thermal debinding in a furnace. As a result, in at least some cases debinding and sintering may take place sequentially within a single furnace. In some embodiments, the techniques may utilize particular materials as binders that allow for a thermal debinding process that does not negatively affect the parts.
    Type: Application
    Filed: November 13, 2020
    Publication date: May 20, 2021
    Applicant: Desktop Metal, Inc.
    Inventors: John Reidy, Christopher Craven, Nihan Tuncer, Animesh Bose, Alexander C. Barbati, Ricardo Fulop, Brian D. Kernan, Karl-Heinz Schofalvi
  • Publication number: 20200376547
    Abstract: A furnace system for printing an object using additive manufacturing. The furnace system may include a furnace chamber; an outlet fluidly coupled to the furnace chamber for removal of an exhaust gas from the furnace chamber; a conduit fluidly coupled to the outlet; an oxygen injector fluidly coupled to the conduit; an isolation system fluidly coupled to the conduit between the furnace chamber and the oxygen injector; and a catalyst enclosure comprising an oxidizing catalyst.
    Type: Application
    Filed: May 27, 2020
    Publication date: December 3, 2020
    Applicant: Desktop Metal, Inc.
    Inventors: Aaron SILIDKER, Richard Remo FONTANA, Brian KERNAN, Mark SOWERBUTTS, Tomek BRZEZINSKI, Ricardo FULOP, Leon FAY, Daniel R. JEPEAL, Nathan WOODARD
  • Patent number: 10759111
    Abstract: A build box associated with a powder bed fabrication system may comprise a housing defining a housing cavity, and a powder print bed disposed within the housing cavity. The powder print bed may be characterized by state information. The build box may further comprise a medium configured to facilitate access to the state information, and a coupling interface for removably engaging the build box with at least one subsystem of the powder bed fabrication system. The state information may comprise one or more state information elements of object identification, object location, current processing state, next subsystem processing step, previous subsystem processing step, object model information, object material composition, and current powder print bed temperature profile. The medium may comprise a memory device coupled with a transceiver. The medium may alternatively comprise an RFID device, or an optically perceivable designator, such as a bar code or QR code.
    Type: Grant
    Filed: March 15, 2018
    Date of Patent: September 1, 2020
    Assignee: Desktop Metal, Inc.
    Inventors: Ricardo Fulop, Alexander Nicholas LeGendre, Jonah Samuel Myerberg, Charles Edward Martin, Justin Cumming, Robert Michael Shydo, Jr., George Hudelson, Jamison Go, Andrew E. Kuklinski, Michael Daniel Santorella
  • Patent number: 10589467
    Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.
    Type: Grant
    Filed: July 11, 2019
    Date of Patent: March 17, 2020
    Assignee: Desktop Metal, Inc.
    Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
  • Patent number: 10500789
    Abstract: A system for de-powdering one or more objects within a powder print bed comprises a build box configured to contain the powder print bed, and a de-powdering subsystem configured to engage the build box. The de-powdering subsystem comprises a vacuum device configured to withdraw loose powder agitated by the air jet device, and a robotic arm configured to convey the vacuum device to one or more locations on the powder print bed. The system may further comprise an air jet device disposed on the robotic arm, the air jet device configured to agitate, with a jet of air, unbound powder within the powder print bed. The system may further comprise a mechanical agitation instrument configured to facilitate agitation of the unbound powder within the powder print bed. The mechanical agitation instrument may be used in conjunction with one or both of the vacuum device and the air jet device.
    Type: Grant
    Filed: September 20, 2018
    Date of Patent: December 10, 2019
    Assignee: Desktop Metal, Inc.
    Inventors: Ricardo Fulop, Robert Michael Shydo, Jr., Jonah Samuel Myerberg, Charles Edward Martin, Justin Cumming, Paul Hoisington, Emanuel M. Sachs
  • Publication number: 20190329500
    Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.
    Type: Application
    Filed: July 11, 2019
    Publication date: October 31, 2019
    Applicant: Desktop Metal, Inc.
    Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
  • Publication number: 20190329502
    Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.
    Type: Application
    Filed: July 11, 2019
    Publication date: October 31, 2019
    Applicant: Desktop Metal, Inc.
    Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
  • Publication number: 20190329501
    Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.
    Type: Application
    Filed: July 11, 2019
    Publication date: October 31, 2019
    Applicant: Desktop Metal, Inc.
    Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
  • Patent number: 10456833
    Abstract: A variety of additive manufacturing techniques can be adapted to fabricate a substantially net shape object from a computerized model using materials that can be debound and sintered into a fully dense metallic part or the like. However, during sintering, the net shape will shrink as binder escapes and the base material fuses into a dense final part. If the foundation beneath the object does not shrink in a corresponding fashion, the resulting stresses throughout the object can lead to fracturing, warping or other physical damage to the object resulting in a failed fabrication. To address this issue, a variety of techniques are disclosed for substrates and build plates that contract in a manner complementary to the object during debinding and sintering.
    Type: Grant
    Filed: January 11, 2018
    Date of Patent: October 29, 2019
    Assignee: Desktop Metals, Inc.
    Inventors: Michael Andrew Gibson, Jonah Samuel Myerberg, Ricardo Fulop, Ricardo Chin, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
  • Patent number: 10406751
    Abstract: A system for separating objects within a stacked powder print bed of nested objects comprises a build box configured to contain the powder print bed. The build box has a build box top and a build box floor. The system further includes an elongated aperture formed in a side wall of the build box, and a de-powdering subsystem configured to mechanically and electrically engage the build box. A separating blade associated with the de-powdering subsystem is configured to be inserted through the elongated aperture and into the powder print bed between a top-most print bed layer of the nested objects and a second print bed layer directly below and contiguous with the top-most layer, thereby forming an isolated powder print bed between the separating blade and the build box top. The unbound powder may be agitated by various techniques and subsequently removed from the objects.
    Type: Grant
    Filed: February 9, 2018
    Date of Patent: September 10, 2019
    Assignee: Desktop Metal, Inc.
    Inventors: Ricardo Fulop, Robert Michael Shydo, Jonah Samuel Myerberg, Charles Edward Martin, Justin Cumming, Paul Hoisington, Emanuel M. Sachs, George Hudelson, Daniel Sachs, Jamison Go, Eric Wong, Alexander K. McCalmont
  • Patent number: 10350682
    Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is fabricated between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. Interface layers suitable for manufacture with an additive manufacturing system may resist the formation of bonds between a support structure and an object during subsequent sintering processes.
    Type: Grant
    Filed: March 24, 2017
    Date of Patent: July 16, 2019
    Assignee: Desktop Metal, Inc.
    Inventors: Jonah Samuel Myerberg, Michael Andrew Gibson, Ricardo Fulop, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
  • Publication number: 20190160529
    Abstract: A materials processing furnace provides for debinding and sintering objects and treating effluent generated by the sintering. A heating chamber maintains a controlled atmosphere for sintering the object. A vacuum pump evacuates an effluent from the heating chamber, and an injector adds a reagent to the evacuated effluent to form a mixed gas. A catalytic converter receives the mixed gas and catalyzes one or more hazardous or offensive compounds of the effluent, thereby converting the effluent to a safer and less offensive exhaust. As a result, the furnace is suitable for operation in an office environment.
    Type: Application
    Filed: November 29, 2018
    Publication date: May 30, 2019
    Inventors: Aaron Silidker, Richard Remo Fontana, Brian Kernan, Mark Sowerbutts, Tomek Brzezinski, Ricardo Fulop, Leon Fay, Daniel R. Jepeal
  • Patent number: 10272492
    Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. The support structure may be a multi-part support structure to mitigate mold lock or facilitate removal from enclosed spaces.
    Type: Grant
    Filed: March 24, 2017
    Date of Patent: April 30, 2019
    Assignee: Desktop Metal, Inc.
    Inventors: Michael Andrew Gibson, Jonah Samuel Myerberg, Ricardo Fulop, Ricardo Chin, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
  • Publication number: 20190118260
    Abstract: Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.
    Type: Application
    Filed: October 25, 2018
    Publication date: April 25, 2019
    Inventors: Peter Alfons Schmitt, Jonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
  • Patent number: 10232443
    Abstract: A printer fabricates an object from a computerized model using a fused filament fabrication process. The shape of an extrusion nozzle may be varied during extrusion to control, e.g., an amount of build material deposited, a shape of extrudate exiting the nozzle, a feature resolution, and the like.
    Type: Grant
    Filed: June 29, 2018
    Date of Patent: March 19, 2019
    Assignee: DESKTOP METAL, INC.
    Inventors: Jonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Anastasios John Hart, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Matthew David Verminski, Emanuel Michael Sachs, Ricardo Chin
  • Publication number: 20190060997
    Abstract: Additive fabrication systems generally use support structures to expand the available range of features and geometries in fabricated objects. For example, when a vertical shelf or cantilever extends from an object, a supplemental support structure may be required to provide a surface for fabrication thereon. This process may become more difficult when, e.g., a part will be subjected to downstream processing steps such as debinding or sintering that impose different design rules. To address these challenges and provide a greater range of flexibility and processing speed, it may be useful in certain circumstances to independently fabricate the object and support structures, and then assemble these structures into a composite item for debinding and sintering. This approach also advantageously facilitates various techniques for spraying, dipping, or otherwise applying a release layer between the support structure and the part so that these separate items do not become fused together during sintering.
    Type: Application
    Filed: October 25, 2018
    Publication date: February 28, 2019
    Inventors: Michael Andrew Gibson, Jonah Samuel Myerberg, Ricardo Fulop, Ricardo Chin, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart