Patents by Inventor Richard Remo Fontana
Richard Remo Fontana 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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Publication number: 20250050413Abstract: 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.Type: ApplicationFiled: March 20, 2024Publication date: February 13, 2025Applicant: Desktop Metal, Inc.Inventors: Jonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Publication number: 20250001500Abstract: Systems and methods are disclosed for forming a three-dimensional object using additive manufacturing. One method includes depositing a first amount of powder material onto a powder print bed of a printing system, spreading the first amount of powder material across the powder print bed to form a first layer, measuring a density of powder material within the powder print bed, and adjusting a parameter of the printing system based on the measured density of the powder material within the powder print bed.Type: ApplicationFiled: February 5, 2024Publication date: January 2, 2025Applicant: Desktop Metal, Inc.Inventors: George Hudelson, Paul Hoisington, Richard Remo Fontana, Emanuel Sachs, Christopher Anthony Craven, Matthew McCambridge
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Publication number: 20240367235Abstract: 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: ApplicationFiled: July 17, 2024Publication date: November 7, 2024Applicant: Desktop Metal, Inc.Inventors: Jonah Samuel Myerberg, Ricardo Fulop, Richard Remo Fontana, Charles Edward Martin, Brett Schuster, Emanuel Michael Sachs
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Patent number: 11969795Abstract: 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.Type: GrantFiled: March 24, 2017Date of Patent: April 30, 2024Assignee: Desktop Metal, Inc.Inventors: Jonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
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Patent number: 11717887Abstract: A method is provided for printing a three-dimensional object. The method comprises, depositing a layer of metal powder onto a powder bed of a three-dimensional printer. A liquid is heated to generate a vapor. The liquid is removed from the vapor to dry the vapor by heating the vapor above a condensation temperature of the liquid. The dry vapor is deposited onto the powder bed of the three-dimensional printer.Type: GrantFiled: July 9, 2020Date of Patent: August 8, 2023Assignee: Desktop Metal, Inc.Inventors: Emanuel M. Sachs, Paul A. Hoisington, Richard Remo Fontana, Jamison Go, Joseph Johnson, George Hudelson, Cassia Lockwood, Michael Goldblatt
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Patent number: 11597011Abstract: 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: GrantFiled: October 25, 2018Date of Patent: March 7, 2023Assignee: Desktop Metal, Inc.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
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Patent number: 11498273Abstract: A system and corresponding method to move build material in a three-dimensional (3D) printing system uses a gripper. The gripper is arranged to apply at least two opposing lateral forces to the build material. The at least two opposing lateral forces are applied to the build material, in conjunction with linear motion of the gripper, for at least a portion of a path the build material travels toward an extrusion head.Type: GrantFiled: July 2, 2019Date of Patent: November 15, 2022Assignee: Desktop Metal, Inc.Inventors: Richard Burnham, John LaPlante, Aaron Preston, Richard Remo Fontana
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Patent number: 11472116Abstract: 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: GrantFiled: July 11, 2019Date of Patent: October 18, 2022Assignee: Desktop Metal, Inc.Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
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Publication number: 20220234104Abstract: A method of metal additive manufacturing, including forming a three-dimensional object as a successive series of layers. At least some of the successive layers is formed by depositing a layer of build material powder on a work surface, depositing a predetermined pattern of fugitive fluid and depositing a predetermined pattern of binder fluid, wherein the predetermined pattern of fugitive fluid improves at least one characteristic of the three-dimensional part.Type: ApplicationFiled: November 8, 2021Publication date: July 28, 2022Applicant: Desktop Metal, Inc.Inventors: Michael A. Gibson, Richard Remo Fontana, George Hudelson, Christopher Benjamin Renner, Paul A. Hoisington, Anna Marie Trump
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Publication number: 20220032377Abstract: Systems and methods are disclosed for forming a three-dimensional object using additive manufacturing. One method includes depositing a first amount of powder material onto a powder print bed of a printing system, spreading the first amount of powder material across the powder print bed to form a first layer, measuring a density of powder material within the powder print bed, and adjusting a parameter of the printing system based on the measured density of the powder material within the powder print bed.Type: ApplicationFiled: July 8, 2021Publication date: February 3, 2022Applicant: Desktop Metal, Inc.Inventors: George Hudelson, Paul A. Hoisington, Richard Remo Fontana, Emanuel Michael Sachs, Christopher Anthony Craven, Matthew McCambridge
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Publication number: 20220016700Abstract: A sintering and debinding system includes a debinding chamber configured to switch between an open state and a closed state, the open state being configured to permit receipt or removal of at least one part within or from the debinding chamber and a sintering chamber operably connected to the debinding chamber and being vertically positioned above or below the debinding chamber. The sintering system also includes a shelf structure configured to receive the at least one part, the shelf structure being movable between the debinding chamber and the sintering chamber and a gate valve configured to switch between an open state and a closed state, the gate valve being configured to selectively permit or block fluid communication between the debinding chamber and the sintering chamber.Type: ApplicationFiled: March 13, 2020Publication date: January 20, 2022Applicant: Desktop Metal, Inc.Inventors: Nathan Woodard, Richard Remo Fontana, Robert Edward Weiss
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Publication number: 20220008991Abstract: A furnace may include an outer wall defining a chamber, the chamber including an internal cavity configured to receive one or more parts, at least one heater positioned within the chamber, the at least one heater being configured to generate temperatures of at least about 800 degrees Celsius within the internal cavity, and a vacuum pump configured to apply a vacuum to at least a portion of the chamber. The furnace may also include at least one layer of inner insulation and at least one layer of outer insulation disposed outward of the inner insulation with respect to the chamber, the at least one layer of outer insulation being sealed with respect to the at least one layer of inner insulation.Type: ApplicationFiled: February 11, 2020Publication date: January 13, 2022Applicant: Desktop Metal, Inc.Inventors: Nathan Woodard, Jonah Samuel Myerberg, Emanuel M Sachs, Richard Remo Fontana, Robert Edward Weiss, Yet-Ming Chiang, Stephen Dipietro, Nicholas Graham Bandiera
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Publication number: 20210283688Abstract: 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: ApplicationFiled: December 14, 2017Publication date: September 16, 2021Applicant: Desktop Metal, Inc.Inventors: Ricardo Fulop, Animesh Bose, Michael Andrew Gibson, Richard Remo Fontana, Jonah Samuel Myerberg
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Publication number: 20210276083Abstract: Devices, systems, and methods are directed to the use of nanoparticles for improving strength fabrication of three-dimensional objects formed through layer-by-layer process in which an ink is delivery of a binder delivered onto successive layers of a powder of inorganic particles in a powder bed. More specifically, nanoparticles of inorganic material can may be introduced into one or more layers of the metal powder in the powder bed and thermally processed to facilitate sinter necking, in the powder bed, of the metal particles forming the three-dimensional object. Such sinter necking in the powder bed can may improve strength of the three-dimensional objects being fabricated and, also or instead, can may reduce the likelihood of defects associated with subsequent processing of the three-dimensional objects (e.g., slumping and shrinking in a final sintering stage and/or inadequate densification of the final part).Type: ApplicationFiled: February 21, 2018Publication date: September 9, 2021Applicant: Desktop Metal, Inc.Inventors: Alexander C. Barbati, Richard Remo Fontana, Michael Andrew Gibson, George Hudelson
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Publication number: 20210237347Abstract: Systems, methods, components, and materials are disclosed for stereolithographic fabrication of three-dimensional, dense objects. A resin including at least one component of a binder system and dispersed particles can be exposed to an activation light source. The activation light source can cure the at least one component of the binder system to form a green object, which can include the at least one component of the binder system and the particles. A dense object can be formed from the green object by removing the at least one component of the binder system in an extraction process and thermally processing particles to coalesce into the dense object.Type: ApplicationFiled: November 14, 2017Publication date: August 5, 2021Applicant: Desktop Metal, Inc.Inventors: Alexander C. Barbati, Richard Remo Fontana, Michael Andrew Gibson, George Hudelson
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Publication number: 20210108856Abstract: A sintering furnace may include a furnace chamber and a retort located within the furnace chamber that receives a part to be heated. The furnace may also include one or more heating elements positioned around the retort and a power controller including power modules connected in series. The power modules may be operably connected to the one or more heating elements and may provide a direct current (DC) power output. A controller may selectively control the power modules to supply power to the one or more heating elements.Type: ApplicationFiled: October 12, 2020Publication date: April 15, 2021Applicant: Desktop Metal, Inc.Inventors: Richard Remo Fontana, Leon Fay
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Publication number: 20210008617Abstract: A method is provided for printing a three-dimensional object. The method comprises, depositing a layer of metal powder onto a powder bed of a three-dimensional printer. A liquid is heated to generate a vapor. The liquid is removed from the vapor to dry the vapor by heating the vapor above a condensation temperature of the liquid. The dry vapor is deposited onto the powder bed of the three-dimensional printer.Type: ApplicationFiled: July 9, 2020Publication date: January 14, 2021Applicant: Desktop Metal, Inc.Inventors: Emanuel M. SACHS, Paul A. HOISINGTON, Richard Remo FONTANA, Jamison GO, Joseph JOHNSON, George HUDELSON, Cassia LOCKWOOD, Michael GOLDBLATT
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Publication number: 20200376547Abstract: 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: ApplicationFiled: May 27, 2020Publication date: December 3, 2020Applicant: Desktop Metal, Inc.Inventors: Aaron SILIDKER, Richard Remo FONTANA, Brian KERNAN, Mark SOWERBUTTS, Tomek BRZEZINSKI, Ricardo FULOP, Leon FAY, Daniel R. JEPEAL, Nathan WOODARD
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Patent number: 10751799Abstract: Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. An electric current delivered to produce the magnetohydrodynamic forces can be controlled between a pulsed electric current and a direct electric current to change the rate of liquid metal ejection from a nozzle. For example, the electric current can be switched between a pulsed electric current and a direct electric current based at least in part on a position of the nozzle along the controlled pattern, providing accuracy of liquid metal deposition along portions of the pattern having more detail and providing speed of liquid metal deposition along portions of the pattern having less detail.Type: GrantFiled: March 6, 2017Date of Patent: August 25, 2020Assignee: Desktop Metal, Inc.Inventors: Emanuel Michael Sachs, Richard Remo Fontana
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Patent number: 10639717Abstract: Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. Porosity of one or more predetermined portions of objects fabricated from an accumulation of liquid metal droplets ejected using magnetohydrodynamic force can be controlled to form interfaces between support structures and parts within the object. Higher porosity along the interfaces, as compared to porosity along the support structures and the parts, can be useful for facilitating separation of the parts from the support structures.Type: GrantFiled: March 6, 2017Date of Patent: May 5, 2020Assignee: Desktop Metal, Inc.Inventors: Richard Remo Fontana, Michael Andrew Gibson