Patents by Inventor Robert Swartz

Robert Swartz 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: 20250109468
    Abstract: A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.
    Type: Application
    Filed: November 12, 2024
    Publication date: April 3, 2025
    Applicant: Impossible Objects, Inc.
    Inventors: Robert Swartz, John Bayldon, Buckley Crist, Eugene Gore
  • Patent number: 12186852
    Abstract: A stacker for a 3D printer apparatus contains a positioning conveyor and a support plate hinged to drop on a signal, whereupon a push plate will push a printed and powdered sheet downward and onto registration pins, to form a stacked register of such sheets.
    Type: Grant
    Filed: August 3, 2021
    Date of Patent: January 7, 2025
    Assignee: Impossible Objects, Inc.
    Inventors: Robert Swartz, Michael Sutin
  • Publication number: 20240424729
    Abstract: A 3D object according to the invention comprises substrate layers infiltrated by a hardened material. The 3D object is fabricated by a method comprising the following steps: Position Powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.
    Type: Application
    Filed: September 3, 2024
    Publication date: December 26, 2024
    Applicant: IMPOSSIBLE OBJECTS, INC.
    Inventors: Robert Swartz, Buckley Crist, Eugene Gore, Joseph M. Jacobson
  • Patent number: 12089731
    Abstract: A coupling system between the frame and the leg assembly of a workstation is described. The coupling system can be configured to selectively attach and detach the leg assembly from the frame. The leg assembly can include an adjustment mechanism. The adjustment mechanism can be configured to adjust the length of the leg. The leg assembly can include a leg coupling feature and the frame can have a frame coupling feature. The leg coupling feature can be configured to engage with the frame coupling feature, for instance to attach the leg to the frame. The workstation can include a latch configured to engage with the leg assembly. Engagement of the latch with the leg assembly can secure a position of the leg with respect to the frame.
    Type: Grant
    Filed: August 23, 2023
    Date of Patent: September 17, 2024
    Assignee: Ergotron, Inc.
    Inventors: Mustafa A. Ergun, Shaun Christopher Lindblad, Michael P. Barros, Michael Anthony Apolloni, Nicholas Robert Swartz, Robert William Fluhrer
  • Publication number: 20240279423
    Abstract: Waste product from any of a variety of processes (injection molding, selective laser sintering) is processed to form powders that have particle size and distribution optimal for a 3D printing technology known as Composite Based Additive Manufacturing (CBAM). Alternative recycling processes include grinding and sieving, emulsion extruding, and liquid-liquid phase separation.
    Type: Application
    Filed: April 29, 2024
    Publication date: August 22, 2024
    Applicant: IMPOSSIBLE OBJECTS, INC.
    Inventors: Robert Swartz, Michael Vasquez, Buckley Crist, Eugene Gore
  • Publication number: 20240278486
    Abstract: A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material comprising engineered powder that is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers. The powder may be emulsion aggregation powder, chemically-produced toner powder, or a combination. It may be a thermoplastic or thermosettable polymer and may include nylon, elastomers, polyolefins, polyethylene, polyether ether ketone, polyimide, polyetherimide, polyphenylene sulfide, polystyrene, polypropylene, polymethyl methacrylate, and polyaryletherketone, or a combination. The powder particles may have a pre-specified controlled shape and/or a non-homogenous composition. Surface treatments and/or additives may be used to control powder flow and charge distribution. Each substrate layer may be a sheet-like structure comprising fibers held together by binder.
    Type: Application
    Filed: April 29, 2024
    Publication date: August 22, 2024
    Applicant: IMPOSSIBLE OBJECTS, INC.
    Inventors: Robert Swartz, Eugene Gore, Buckley Crist, Michael Vasquez, John Bayldon
  • Publication number: 20240254344
    Abstract: Processes for producing CBAM parts and/or components, including resulting articles, are disclosed. In one process, a fiber substrate binder possessing a flash point temperature greater than a predetermined processing temperature is used.
    Type: Application
    Filed: January 26, 2024
    Publication date: August 1, 2024
    Applicant: IMPOSSIBLE OBJECTS, INC.
    Inventors: Robert Swartz, Michael Vasquez, Buckley Crist, John Bayldon, Eugene Gore
  • Patent number: 12042826
    Abstract: In accordance with a preferred embodiment of the invention, there is disclosed an article of manufacture for cleaning the external surface of a 3D printer's extruder comprising: A filament adherent surface capable of removing unwanted material and providing samples of post-extruder filament material for examination, an oil absorbing volume capable of removing and storing for disposal oils and other hydrophobic fluid materials unintentionally or inadvertently on the external extruder surface, a thermal insulating layer to protect the hand cleaning the external extruder volume, a cowoven material for improving structural strength, and a perimeter edge modification to improve material removal.
    Type: Grant
    Filed: December 12, 2019
    Date of Patent: July 23, 2024
    Inventor: Mitchell Robert Swartz
  • Patent number: 11969938
    Abstract: A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material comprising engineered powder that is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers. The powder may be emulsion aggregation powder, chemically-produced toner powder, or a combination. It may be a thermoplastic or thermosettable polymer and may include nylon, elastomers, polyolefins, polyethylene, polyether ether ketone, polyimide, polyetherimide, polyphenylene sulfide, polystyrene, polypropylene, polymethyl methacrylate, and polyaryletherketone, or a combination. The powder particles may have a pre-specified controlled shape and/or a non-homogenous composition. Surface treatments and/or additives may be used to control powder flow and charge distribution. Each substrate layer may be a sheet-like structure comprising fibers held together by binder.
    Type: Grant
    Filed: January 28, 2020
    Date of Patent: April 30, 2024
    Assignee: Impossible Objects, Inc.
    Inventors: Robert Swartz, Eugene Gore, Buckley Crist, Michael Vasquez, John Bayldon
  • Patent number: 11969954
    Abstract: A method and apparatus for resistive heating usable in composite-based additive manufacturing is disclosed. The method includes providing a prepared stack of substrate sheets, placing the stack between electrode assemblies of a compression device, applying a current to thereby heat the stack to a final temperature to liquefy applied powder, compressing the stack to a final height, cooling the stack, and removing the cooled, compressed stack from the compression device. The apparatus comprises at least two plates, a power supply for providing current, a first electrode assembly and a second electrode assembly.
    Type: Grant
    Filed: March 11, 2021
    Date of Patent: April 30, 2024
    Assignee: Impossible Objects, Inc.
    Inventors: Robert Swartz, John Bayldon, Buckley Crist, Eugene Gore
  • Patent number: 11970584
    Abstract: Waste product from any of a variety of processes (injection molding, selective laser sintering) is processed to form powders that have particle size and distribution optimal for a 3D printing technology known as Composite Based Additive Manufacturing (CBAM). Alternative recycling processes include grinding and sieving, emulsion extruding, and liquid-liquid phase separation.
    Type: Grant
    Filed: January 3, 2022
    Date of Patent: April 30, 2024
    Assignee: Impossible Objects, Inc.
    Inventors: Robert Swartz, Michael Vasquez, Buckley Crist, Eugene Gore
  • Patent number: 11904536
    Abstract: An apparatus and method for the automated manufacturing of three-dimensional (3D) composite-based objects is disclosed. The apparatus comprises a material feeder, a printer, a powder system, a transfer system, and optionally a fuser. The method comprises inserting a stack of substrate sheets into a material feeder, transferring a sheet of the stack from the material feeder to a printer, depositing fluid on the single sheet while the sheet rests on a printer platen, transferring the sheet from the printer to a powder system, depositing powder onto the single sheet such that the powder adheres to the areas of the sheet onto which the printer has deposited fluid, removing any powder that did not adhere to the sheet, optionally melting the powder on the substrate, and repeating the steps for as many additional sheets as required for making a specified 3D object.
    Type: Grant
    Filed: August 16, 2022
    Date of Patent: February 20, 2024
    Assignee: Impossible Objects, Inc.
    Inventors: Robert Swartz, Eugene Gore, Buckley Crist, John Bayldon, Chris Wagner, Nicholas Tarzian, Evangeline Su
  • Patent number: 11904549
    Abstract: A felt gripper head contains two regions of felt material each on plates that slide and form a slight angle with respect to each other during engagement with a fibrous substrate material.
    Type: Grant
    Filed: August 3, 2021
    Date of Patent: February 20, 2024
    Assignee: Impossible Objects, Inc.
    Inventors: James Brough, Robert Swartz, Nick Tarzian, Eugene Gore
  • Patent number: 11904532
    Abstract: A system and method for lifting substrate sheets off of a stack of porous sheets one at a time, even though the sheets tend to stick together. A felt tamp is lowered onto the stack of sheets, and as the tamp is raised, a set of edge flickers create a downward force on the corners of the top sheet. This causes the edges of the top sheet to bend downward slightly just enough to pry the second sheet loose from the top sheet. The tamp can then be further raised with only the top sheet adhering to the felt, and the lifted sheet can be deposited at the next station in the process. Periodically, a brush is used to renew the surface of the felt to prevent matting of the felt fibers.
    Type: Grant
    Filed: January 23, 2021
    Date of Patent: February 20, 2024
    Assignee: Impossible Objects, Inc.
    Inventors: Robert Swartz, James Brough, Eugene Gore
  • Publication number: 20230389693
    Abstract: A coupling system between the frame and the leg assembly of a workstation is described. The coupling system can be configured to selectively attach and detach the leg assembly from the frame. The leg assembly can include an adjustment mechanism. The adjustment mechanism can be configured to adjust the length of the leg. The leg assembly can include a leg coupling feature and the frame can have a frame coupling feature. The leg coupling feature can be configured to engage with the frame coupling feature, for instance to attach the leg to the frame. The workstation can include a latch configured to engage with the leg assembly. Engagement of the latch with the leg assembly can secure a position of the leg with respect to the frame.
    Type: Application
    Filed: August 23, 2023
    Publication date: December 7, 2023
    Inventors: Mustafa A. Ergun, Shaun Christopher Lindblad, Michael P. Barros, Michael Anthony Apolloni, Nicholas Robert Swartz, Robert William Fluhrer
  • Publication number: 20230391976
    Abstract: Waste product from any of a variety of processes (injection molding, selective laser sintering) is processed to form powders that have particle size and distribution optimal for a 3D printing technology known as Composite Based Additive Manufacturing (CBAM). Alternative recycling processes include grinding and sieving, emulsion extruding, and liquid-liquid phase separation.
    Type: Application
    Filed: January 3, 2022
    Publication date: December 7, 2023
    Applicant: IMPOSSIBLE OBJECTS, INC.
    Inventors: Robert Swartz, Michael Vasquez, Buckley Crist, Eugene Gore
  • Patent number: 11806931
    Abstract: A bulk ink bag system in a composite-based additive manufacturing process (CBAM) keeps the inkjet heads (cartridges) on printers filled to the proper level of fluid at all times while the process runs. The system includes gravity fed fluid delivery without requiring pumps; is simple to connect and disconnect to system plumbing; has the ability to change ink bags without interrupting the print job or introducing air bubbles into the ink supply; and has the ability to disconnect partially used bags and reconnect them later.
    Type: Grant
    Filed: January 23, 2021
    Date of Patent: November 7, 2023
    Assignee: Impossible Objects, Inc.
    Inventors: Robert Swartz, Leonard Wanger, John Bayldon, Drew Marschner, Michael Rohrer, Gintaras Vaisnys, Giovanni Meier
  • Patent number: 11806935
    Abstract: A method of residual ink removal in an ink-dependent 3-D printing process includes pre-heating a build block to an evaporation temperature. This is preferably done after stacking and before compression. Later compression will then involve a higher temperature to allow fusing of thermoplastic material in the build block, but without residual ink.
    Type: Grant
    Filed: May 19, 2021
    Date of Patent: November 7, 2023
    Assignee: Impossible Objects, Inc.
    Inventors: Robert Swartz, Eugene Gore, Buckley Crist, Darren Fill, John Bayldon
  • Publication number: 20230339174
    Abstract: A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material. Each substrate layer is a sheet-like structure that comprises fibers held together by a sodium silicate binder. The substrate layer material may be non-woven or woven. The substrate layer may be a non-woven fiber veil bound by a sodium silicate binder. The fibers may optionally include carbon fibers, ceramic fibers, polymer fibers, glass fibers, metal fibers, or a combination thereof.
    Type: Application
    Filed: June 8, 2023
    Publication date: October 26, 2023
    Applicant: Impossible Objects, Inc.
    Inventors: Robert Swartz, Eugene Gore, Buckley Crist, Michael Vasquez, John Bayldon
  • Publication number: 20230313352
    Abstract: A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.
    Type: Application
    Filed: June 8, 2023
    Publication date: October 5, 2023
    Applicant: Impossible Objects, Inc.
    Inventors: Robert Swartz, John Bayldon, Buckley Crist, Eugene Gore