Patents by Inventor Samuel VanDenBerg
Samuel VanDenBerg 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: 11813793Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a continuous reinforcement, a second supply configured to hold a matrix separate from the continuous reinforcement, and a wetting mechanism in separate communication with the first and second supplies and configured to discharge the continuous reinforcement wetted with the matrix. The system may also include a controller programmed to selectively pressurize the second supply to direct the matrix to the wetting mechanism.Type: GrantFiled: July 26, 2021Date of Patent: November 14, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20230191697Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.Type: ApplicationFiled: February 16, 2023Publication date: June 22, 2023Applicant: Continuous Composites, Inc.Inventors: TREVOR DAVID BUDGE, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20230122355Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.Type: ApplicationFiled: November 29, 2022Publication date: April 20, 2023Applicant: Continuous Composites Inc.Inventors: TREVOR DAVID BUDGE, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Patent number: 11613080Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.Type: GrantFiled: July 26, 2021Date of Patent: March 28, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20230070818Abstract: A nozzle is disclosed for use in an additive manufacturing print head. The nozzle may include a body having a central passage with an entrant end and an exit end, and a shoulder protruding radially outward from the body at a location between the entrant and exit ends. A groove may be formed within an outer surface of the body at a location between the shoulder and the entrant end. The groove may be configured to receive a seal.Type: ApplicationFiled: September 2, 2022Publication date: March 9, 2023Applicant: Continuous Composites Inc.Inventors: Andrew John Overby, Nathan Andrew Stranberg, Stephen Tyler Wilson, Sam Armstrong, Maxwell Joseph Johnson, Samuel VanDenBerg
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Publication number: 20230073782Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material, a leading device, and a trailing device pivotally connected to the leading device. The leading device may be configured to engage and move over the material after discharge. The trailing device may be configured to engage and move over the material at a location trailing the leading device.Type: ApplicationFiled: September 2, 2022Publication date: March 9, 2023Applicant: Continuous Composites Inc.Inventors: Andrew John Overby, Nathan Andrew Stranberg, Stephen Tyler Wilson, Sam Armstrong, Maxwell Joseph Johnson, Samuel VanDenBerg
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Publication number: 20230071473Abstract: A method is disclosed for additively manufacturing a structure. The method may include discharging from a print head a first layer of material inward of an outer boundary of the structure. The method may also include discharging from the print head a second layer of material adjacent the first layer and cantilevering past an edge of the first layer. The method may further include compacting a portion of the second layer of material cantilevered past the edge of the first layer to extend into and form a portion of the first layer of material.Type: ApplicationFiled: September 2, 2022Publication date: March 9, 2023Applicant: Continuous Composites Inc.Inventors: Andrew John Overby, Nathan Andrew Stranberg, Stephen Tyler Wilson, Sam Armstrong, Maxwell Joseph Johnson, Samuel VanDenBerg
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Publication number: 20230071513Abstract: A system is disclosed for additively manufacturing an object. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a supply module configured to hold a reinforcement, and a wetting module. The wetting module may include a body with an inlet configured to separately receive the reinforcement and a matrix, and an outlet configured to discharge the reinforcement wetted with the matrix. The print head may also include a teasing mechanism disposed between the inlet and the outlet. The teasing mechanism may have multiple operating positions configured to affect varying levels of pressure against the reinforcement.Type: ApplicationFiled: September 2, 2022Publication date: March 9, 2023Applicant: Continuous Composites Inc.Inventors: Andrew John Overby, Nathan Andrew Stranberg, Stephen Tyler Wilson, Sam Armstrong, Maxwell Joseph Johnson, Samuel VanDenBerg
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Publication number: 20230073014Abstract: A system is disclosed for additively manufacturing an object. The system may include a first module configured to discharge a composite material including a continuous reinforcement and a matrix, and a cutting module located downstream of the first module and configured to sever the continuous reinforcement discharging from the first module. The cutting module may include a cutting mechanism configured to engage the continuous reinforcement, and a guide moveable to selectively abut the reinforcement during engagement of the reinforcement by the cutting mechanism.Type: ApplicationFiled: September 2, 2022Publication date: March 9, 2023Applicant: Continuous Composites Inc.Inventors: Andrew John Overby, Nathan Andrew Stranberg, Stephen Tyler Wilson, Sam Armstrong, Maxwell Joseph Johnson, Samuel VanDenBerg
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Patent number: 11541603Abstract: A print head is disclosed for use in an additive manufacturing system. The print head may include an outlet configured to discharge a material, and a compacting device mounted to trail behind the outlet during movement of the print head in a normal direction. The print head may also include a spring configured to bias the compacting device against the material and to allow movement of the compacting device in a direction parallel with a discharge direction of the material through the outlet, and a locker configured to selectively lock a position of the compacting device relative to the outlet.Type: GrantFiled: May 21, 2020Date of Patent: January 3, 2023Assignee: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Stephen Tyler Wilson, Samuel VanDenBerg
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Patent number: 11541598Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.Type: GrantFiled: July 28, 2021Date of Patent: January 3, 2023Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Patent number: 11465348Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a supply of continuous reinforcement, an outlet configured to discharge the continuous reinforcement, and a tensioning module disposed between the supply and outlet. The tensioning module may be configured to generate a signal indicative of a tension in the continuous reinforcement. The system may also include a processor programmed to selectively cause the supply to dispense the continuous reinforcement based on the signal.Type: GrantFiled: July 26, 2021Date of Patent: October 11, 2022Assignee: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20220242040Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to discharge a continuous reinforcement that is at least partially coated in a matrix, and a compactor configured to compact the continuous reinforcement and the matrix. The system may also include a cure enhancer configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor.Type: ApplicationFiled: April 21, 2022Publication date: August 4, 2022Applicant: Continuous Composites Inc.Inventors: Kyle Frank Cummings, Marcus Raye Vincent Brodie, Samuel VanDenBerg, Ryan C. Stockett
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Patent number: 11358331Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to discharge a continuous reinforcement that is at least partially coated in a matrix, and a compactor configured to compact the continuous reinforcement and the matrix. The system may also include a cure enhancer configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor.Type: GrantFiled: July 18, 2019Date of Patent: June 14, 2022Assignee: Continuous Composites inc.Inventors: Kyle Frank Cummings, Marcus Raye Vincent Brodie, Samuel VanDenBerg, Ryan C. Stockett
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Publication number: 20220080660Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet; a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface, and a cutting module located between the outlet and the compactor. The compactor and the cutting module may be configured to move together relative to the outlet.Type: ApplicationFiled: July 26, 2021Publication date: March 17, 2022Applicant: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20220080659Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include an outlet configured to discharge a material in a trajectory along a central axis of the outlet, and a compactor disposed downstream of the outlet relative to the trajectory and configured to press the material transversely against an adjacent surface. The outlet may be configured to translate relative to the compacting module.Type: ApplicationFiled: July 26, 2021Publication date: March 17, 2022Applicant: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20220080653Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a liquid matrix, a second supply configured to hold a continuous reinforcement, and a wetting module configured to separately receive the liquid matrix and the continuous reinforcement from the first and second supplies, respectively, and to discharge a composite material including the continuous reinforcement wetted with the liquid matrix. The wetting module may include a body forming an internal chamber having an upstream open end and a downstream open end, an entrant nozzle disposed within the upstream open end and configured to receive the continuous reinforcement, and an exit nozzle disposed within the downstream closed end and configured to discharge the composite material.Type: ApplicationFiled: July 28, 2021Publication date: March 17, 2022Applicant: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson
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Publication number: 20220080658Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a support, and a print head operatively connected to and moveable by the support. The print head may include a first supply configured to hold a continuous reinforcement, a second supply configured to hold a matrix separate from the continuous reinforcement, and a wetting mechanism in separate communication with the first and second supplies and configured to discharge the continuous reinforcement wetted with the matrix. The system may also include a controller programmed to selectively pressurize the second supply to direct the matrix to the wetting mechanism.Type: ApplicationFiled: July 26, 2021Publication date: March 17, 2022Applicant: Continuous Composites Inc.Inventors: Trevor David Budge, Brock Adam Jahner, Jeremiah R. Smith, Nathan Andrew Stranberg, Andrew Michael Stulc, Samuel VanDenBerg, Stephen Tyler Wilson, Andrew John Overby
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Publication number: 20200376759Abstract: A print head is disclosed for use in an additive manufacturing system. The print head may include an outlet configured to discharge a material, and a compacting device mounted to trail behind the outlet during movement of the print head in a normal direction. The print head may also include a spring configured to bias the compacting device against the material and to allow movement of the compacting device in a direction parallel with a discharge direction of the material through the outlet, and a locker configured to selectively lock a position of the compacting device relative to the outlet.Type: ApplicationFiled: May 21, 2020Publication date: December 3, 2020Applicant: Continuous Composites Inc.Inventors: Nathan Andrew Stranberg, Stephen Tyler Wilson, Samuel VanDenBerg
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Publication number: 20200156315Abstract: A system is disclosed for additively manufacturing a composite structure. The system may include a print head configured to discharge a continuous reinforcement that is at least partially coated in a matrix, and a compactor configured to compact the continuous reinforcement and the matrix. The system may also include a cure enhancer configured to direct a path of cure energy toward the matrix after discharge, wherein the path of cure energy passes through at least a portion of the compactor.Type: ApplicationFiled: July 18, 2019Publication date: May 21, 2020Applicant: Continuous Composites Inc.Inventors: Kyle Frank Cummings, Marcus Raye Vincent Brodie, Samuel VanDenBerg, Ryan C. Stockett