Patents by Inventor Scott G. VAAL
Scott G. VAAL 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: 20240100773Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: ApplicationFiled: December 5, 2023Publication date: March 28, 2024Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Patent number: 11911953Abstract: An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.Type: GrantFiled: July 1, 2021Date of Patent: February 27, 2024Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Scott G. Vaal
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Publication number: 20240017489Abstract: A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.Type: ApplicationFiled: July 14, 2023Publication date: January 18, 2024Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Scott G. VAAL, Nicolas C. VOTE
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Patent number: 11872752Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: GrantFiled: February 24, 2023Date of Patent: January 16, 2024Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Patent number: 11833752Abstract: An additive manufacturing system may include a carrier, a set of rails coupled to the carrier, and a transition housing movably attached to the set of rails. The additive manufacturing system may include an extruder having an extruder barrel coupled to the transition housing, and a melt pump fixedly attached to the carrier. The melt pump may be in fluid communication with the extruder barrel. Additionally, the additive manufacturing system may include a nozzle in fluid communication with the melt pump, and a roller rotatable about the nozzle.Type: GrantFiled: June 23, 2021Date of Patent: December 5, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Brian S. Smiddy, John Fuquay, Scott G. Vaal
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Patent number: 11724453Abstract: A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.Type: GrantFiled: December 22, 2021Date of Patent: August 15, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Scott G. Vaal, Nicolas C. Vote
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Publication number: 20230219296Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: ApplicationFiled: February 24, 2023Publication date: July 13, 2023Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Nicolas VOTE, Robert GAESSER, Brian S. SMIDDY, Scott G. VAAL
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Patent number: 11607845Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: GrantFiled: June 13, 2022Date of Patent: March 21, 2023Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Patent number: 11554538Abstract: An additive manufacturing apparatus includes a material container having a hollow interior configured to receive a material and an extruder connected below the material container to receive the material from the material container. The additive manufacturing apparatus includes a material removal device including an actuator configured to activate the material removal device to dislodge retained material from within the hollow interior of the material container and a drain passage configured to receive the dislodged material and guide the material to an exterior of the additive manufacturing apparatus.Type: GrantFiled: July 19, 2022Date of Patent: January 17, 2023Assignee: Thermwood CorporationInventors: Brian S. Smiddy, Scott G. Vaal
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Patent number: 11472108Abstract: An additive manufacturing apparatus includes a material container having a hollow interior configured to receive a material and an extruder connected below the material container to receive the material from the material container. The additive manufacturing apparatus includes a material removal device including an actuator configured to activate the material removal device to dislodge retained material from within the hollow interior of the material container and a drain passage configured to receive the dislodged material and guide the material to an exterior of the additive manufacturing apparatus.Type: GrantFiled: October 28, 2021Date of Patent: October 18, 2022Assignee: THERMWOOD CORPORATIONInventors: Brian S. Smiddy, Scott G. Vaal
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Publication number: 20220305729Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: ApplicationFiled: June 13, 2022Publication date: September 29, 2022Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Nicolas VOTE, Robert GAESSER, Brian S. SMIDDY, Scott G. VAAL
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Patent number: 11383438Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: GrantFiled: August 6, 2021Date of Patent: July 12, 2022Assignee: THERMWOOD CORPORATIONInventors: Kenneth J. Susnjara, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Publication number: 20220111589Abstract: A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.Type: ApplicationFiled: December 22, 2021Publication date: April 14, 2022Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Scott G. VAAL, Nicolas C. VOTE
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Publication number: 20220040922Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder, the extruder having an opening dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle in fluid communication with the gear pump for depositing the at least partially melted material.Type: ApplicationFiled: October 27, 2021Publication date: February 10, 2022Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Scott G. VAAL, Brian S. SMIDDY, Jonathan I. FUQUAY
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Patent number: 11235524Abstract: A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.Type: GrantFiled: April 8, 2021Date of Patent: February 1, 2022Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Scott G. Vaal, Nicolas C. Vote
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Patent number: 11220053Abstract: Embodiments of the present disclosure are drawn to an additive manufacturing system, which may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. An applicator head may surround at least a portion of a proximal region of the nozzle. The applicator head may include a housing, a cooling inlet for receiving a coolant into the housing, a cooling outlet configured to allow the coolant to exit the housing, and an air inlet. A roller may be mounted on the applicator head to one side of the outlet of the nozzle. The roller may include an air outlet, wherein a flow path connects the air inlet and the air outlet so that air enters the air inlet and exits the air outlet. The roller may also include a plurality of holes located on an external surface of the roller.Type: GrantFiled: September 4, 2020Date of Patent: January 11, 2022Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Scott G. Vaal, Brian S. Smiddy
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Publication number: 20210362412Abstract: A system for additive manufacturing includes a nozzle configured to translate along a first axis, a second axis perpendicular to the first axis, and a third axis orthogonal to the first and second axes, wherein the nozzle is operably coupled to: an extruder having an outlet and including a screw disposed within a barrel, and a pump having an inlet and an outlet. The inlet is coupled to the extruder, and the outlet is in fluid communication with the nozzle. The system also includes a controller configured to adjust a speed of the pump with respect to a speed of the screw to apply a target pressure at the outlet of the extruder.Type: ApplicationFiled: August 6, 2021Publication date: November 25, 2021Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Nicolas Vote, Robert Gaesser, Brian S. Smiddy, Scott G. Vaal
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Patent number: 11179893Abstract: Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder, the extruder having an opening dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle in fluid communication with the gear pump for depositing the at least partially melted material.Type: GrantFiled: January 27, 2021Date of Patent: November 23, 2021Assignee: Thermwood CorporationInventors: Kenneth J. Susnjara, Scott G. Vaal, Brian S. Smiddy, Jonathan I. Fuquay
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Publication number: 20210347107Abstract: An additive manufacturing device and method for delivering a flowable material from a nozzle of a programmable computer numeric control (CNC) machine, and compressing the flowable material with a compression roller. In one embodiment, the device includes a nozzle configured to deposit a flowable material on a surface; and a roller configured to compress the deposited flowable material, wherein the roller comprises: a flat center portion having a constant diameter; and opposed end portions, wherein each end portion extends outwardly from the flat center portion, and wherein a radially outermost surface of each end portion is angled relative a rotational axis of the roller.Type: ApplicationFiled: July 1, 2021Publication date: November 11, 2021Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Scott G. VAAL
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Publication number: 20210347118Abstract: An additive manufacturing apparatus includes an extruder and a gear pump in fluid communication with extruder. The additive manufacturing apparatus also includes a nozzle in fluid communication with the gear pump. The extruder is connected to a guide member such that at least a portion of the extruder is configured to expand and move along the guide member according to a thermal expansion of the extruder.Type: ApplicationFiled: July 14, 2021Publication date: November 11, 2021Applicant: Thermwood CorporationInventors: Kenneth J. SUSNJARA, Brian S. SMIDDY, John FUQUAY, Scott G. VAAL