Patents by Inventor Stephen T. Connor

Stephen T. Connor 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).

  • Patent number: 12257659
    Abstract: An assembly for controlling waste material during a hybrid subtractive and additive manufacturing process is disclosed, including a machining tool held in a holder, a shroud disposed around the machining tool, and one or more ports configured to create a negative pressure within the shroud. A method of constraining waste material during a hybrid subtractive and additive manufacturing process of a part includes adding an amount of material to a part being additively manufactured, transforming the amount of material that was added, manipulating a tool to machine a portion of the part being additively manufactured and generating a waste material, sealing a portion of the tool and covering a portion of the part with a shroud, and applying a negative pressure to create an airflow to prevent the waste material from exiting the shroud.
    Type: Grant
    Filed: September 29, 2021
    Date of Patent: March 25, 2025
    Assignee: MANTLE INC.
    Inventors: Stephen T. Connor, Fabio Zurcher, Brad Eaton, Matthew McKay
  • Publication number: 20250050588
    Abstract: A method for fabricating a physical object is disclosed, including receiving a 3D representation of the physical object, modifying the 3d representation of the physical object, determining a fabrication strategy for forming the physical object, generating fabrication instructions for formation of the physical object based upon the step of determining the fabrication strategy, and fabricating the physical object based upon the step of generating fabrication instructions. The method and system is configured to modify a three-dimensional (3D) representation of a physical object to, in part, compensate for material shrinkage and material removal, improve surface finish, and decrease feature damage during fabrication of the physical object.
    Type: Application
    Filed: August 9, 2024
    Publication date: February 13, 2025
    Applicant: MANTLE
    Inventors: Stephen T. Connor, Michael A. Kottman
  • Publication number: 20250026939
    Abstract: A material and method are disclosed such that the material can be used to form functional metal pieces by producing an easily sintered layered body of dried metal paste. On a microstructural level, when dried, the metal paste creates a matrix of porous metal scaffold particles with infiltrant metal particles, which are positioned interstitially in the porous scaffold's interstitial voids. For this material to realize mechanical and processing benefits, the infiltrant particles are chosen such that they pack in the porous scaffold piece in a manner which does not significantly degrade the packing of the scaffold particles and so that they can also infiltrate the porous scaffold on heating. The method of using this paste provides a technique with high rate and resolution of metal part production due to a hybrid deposition/removal process.
    Type: Application
    Filed: October 3, 2024
    Publication date: January 23, 2025
    Applicant: MANTLE INC.
    Inventors: Stephen T. CONNOR, James R. GROVES, Theodore C. SOROM
  • Patent number: 12139638
    Abstract: A material and method are disclosed such that the material can be used to form functional metal pieces by producing an easily sintered layered body of dried metal paste. On a microstructural level, when dried, the metal paste creates a matrix of porous metal scaffold particles with infiltrant metal particles, which are positioned interstitially in the porous scaffold's interstitial voids. For this material to realize mechanical and processing benefits, the infiltrant particles are chosen such that they pack in the porous scaffold piece in a manner which does not significantly degrade the packing of the scaffold particles and so that they can also infiltrate the porous scaffold on heating. The method of using this paste provides a technique with high rate and resolution of metal part production due to a hybrid deposition/removal process.
    Type: Grant
    Filed: September 18, 2018
    Date of Patent: November 12, 2024
    Assignee: MANTLE INC.
    Inventors: Stephen T. Connor, James R. Groves, Theodore C. Sorom
  • Publication number: 20240319710
    Abstract: A method for facilitating part fabrication, such as by automated toolpath generation, can include one or more of: receiving a virtual part; modifying the virtual part; and/or determining toolpaths to fabricate the target part. The toolpaths preferably define an ordered series of additive and subtractive toolpaths, more preferably wherein the additive and subtractive toolpaths are interleaved, which can function to achieve high manufacturing efficiency and/or performance. The method can additionally or alternatively include: generating machine instructions based on the toolpaths; fabricating the target part based on the machine instructions; calibrating the fabrication system; and/or any other suitable elements.
    Type: Application
    Filed: June 7, 2024
    Publication date: September 26, 2024
    Applicant: Mantle Inc.
    Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore C. Sorom
  • Patent number: 12032356
    Abstract: A method for facilitating part fabrication, such as by automated toolpath generation, can include one or more of: receiving a virtual part; modifying the virtual part; and/or determining toolpaths to fabricate the target part. The toolpaths preferably define an ordered series of additive and subtractive toolpaths, more preferably wherein the additive and subtractive toolpaths are interleaved, which can function to achieve high manufacturing efficiency and/or performance. The method can additionally or alternatively include: generating machine instructions based on the toolpaths; fabricating the target part based on the machine instructions; calibrating the fabrication system; and/or any other suitable elements.
    Type: Grant
    Filed: April 19, 2023
    Date of Patent: July 9, 2024
    Assignee: Mantle Inc.
    Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom
  • Publication number: 20240208136
    Abstract: A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.
    Type: Application
    Filed: January 26, 2024
    Publication date: June 27, 2024
    Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
  • Patent number: 11919224
    Abstract: A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.
    Type: Grant
    Filed: December 6, 2022
    Date of Patent: March 5, 2024
    Assignee: Mantle Inc.
    Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
  • Publication number: 20240042697
    Abstract: A system for, and method of, printing a three-dimensional (3D) object are presented. The techniques can include obtaining a three-dimensional virtual representation of the object; obtaining first and second 3D printing strategies; obtaining first and second virtual extrusion renderings, wherein the virtual extrusion renderings corresponds to first and second toolpaths for a deposition layer of the object according to the first and second 3D printing strategies; performing first and second comparisons of, respectively, the first and second virtual extrusion renderings to a corresponding portion of the three-dimensional virtual representation of the object; determining, based on the first and second comparisons, respectively, first and second regions of the object that do not intersect the virtual extrusion rendering; providing an output 3D printing strategy for the deposition layer of the object selected from among the first and second 3D printing strategies based on the first and second regions of the object.
    Type: Application
    Filed: August 8, 2022
    Publication date: February 8, 2024
    Applicant: MANTLE INC.
    Inventors: Stephen T. Connor, Nilesh Dixit, Ivan Ionov
  • Patent number: 11813788
    Abstract: A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.
    Type: Grant
    Filed: June 28, 2022
    Date of Patent: November 14, 2023
    Assignee: Mantle Inc.
    Inventors: Stephen T. Connor, Theodore C Sorom, James R. Groves
  • Patent number: 11761706
    Abstract: A sintering furnace can include an outer shell defining an internal volume a reactive agent inlet configured to introduce a reactive agent into the internal volume; an insulation chamber within the outer shell; and a retort configured to retain an object. A method of operating a sintering furnace can include sintering a part precursor within a retort arranged within a chamber, wherein the chamber defines an intermediate volume between the retort and the chamber, wherein a sintering byproduct is oxidized within the intermediate volume.
    Type: Grant
    Filed: March 14, 2022
    Date of Patent: September 19, 2023
    Assignee: Mantle Inc.
    Inventors: Stephen T. Connor, Fabio Zurcher, Thale Smith
  • Publication number: 20230251626
    Abstract: A method for facilitating part fabrication, such as by automated toolpath generation, can include one or more of: receiving a virtual part; modifying the virtual part; and/or determining toolpaths to fabricate the target part. The toolpaths preferably define an ordered series of additive and subtractive toolpaths, more preferably wherein the additive and subtractive toolpaths are interleaved, which can function to achieve high manufacturing efficiency and/or performance. The method can additionally or alternatively include: generating machine instructions based on the toolpaths; fabricating the target part based on the machine instructions; calibrating the fabrication system; and/or any other suitable elements.
    Type: Application
    Filed: April 19, 2023
    Publication date: August 10, 2023
    Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom
  • Patent number: 11662711
    Abstract: A method for facilitating part fabrication, such as by automated toolpath generation, can include one or more of: receiving a virtual part; modifying the virtual part; and/or determining toolpaths to fabricate the target part. The toolpaths preferably define an ordered series of additive and subtractive toolpaths, more preferably wherein the additive and subtractive toolpaths are interleaved, which can function to achieve high manufacturing efficiency and/or performance. The method can additionally or alternatively include: generating machine instructions based on the toolpaths; fabricating the target part based on the machine instructions; calibrating the fabrication system; and/or any other suitable elements.
    Type: Grant
    Filed: July 12, 2022
    Date of Patent: May 30, 2023
    Assignee: Mantle Inc.
    Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom
  • Publication number: 20230104107
    Abstract: A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.
    Type: Application
    Filed: December 6, 2022
    Publication date: April 6, 2023
    Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
  • Publication number: 20230037565
    Abstract: A sintering furnace can include an outer shell defining an internal volume a reactive agent inlet configured to introduce a reactive agent into the internal volume; an insulation chamber within the outer shell; and a retort configured to retain an object. A method of operating a sintering furnace can include sintering a part precursor within a retort arranged within a chamber, wherein the chamber defines an intermediate volume between the retort and the chamber, wherein a sintering byproduct is oxidized within the intermediate volume.
    Type: Application
    Filed: October 21, 2022
    Publication date: February 9, 2023
    Inventors: Stephen T. Connor, Fabio Zurcher, Thale Smith
  • Publication number: 20230028908
    Abstract: A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.
    Type: Application
    Filed: September 30, 2022
    Publication date: January 26, 2023
    Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
  • Publication number: 20220339703
    Abstract: A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.
    Type: Application
    Filed: June 28, 2022
    Publication date: October 27, 2022
    Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
  • Publication number: 20220342385
    Abstract: A method for facilitating part fabrication, such as by automated toolpath generation, can include one or more of: receiving a virtual part; modifying the virtual part; and/or determining toolpaths to fabricate the target part. The toolpaths preferably define an ordered series of additive and subtractive toolpaths, more preferably wherein the additive and subtractive toolpaths are interleaved, which can function to achieve high manufacturing efficiency and/or performance. The method can additionally or alternatively include: generating machine instructions based on the toolpaths; fabricating the target part based on the machine instructions; calibrating the fabrication system; and/or any other suitable elements.
    Type: Application
    Filed: July 12, 2022
    Publication date: October 27, 2022
    Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom
  • Publication number: 20220331873
    Abstract: Transformation steps including drying are incorporated into a process of additive manufacturing of a part. Processes and devices for achieving a transformation are described. A cycle of manufacturing is begun by adding a feedstock such as a metal paste to form a partial part followed by a transformation of the added feedstock, such as removing solvent from a metal paste, to form a transformed part suitable for a manipulation step such as machining. Inclusion of a manipulation process such as machining comprises a single cycle of a manufacturing process. One or more said cycles comprise the process of producing a completed part suitable for further processing such as sintering in the case of a metal paste feedstock to form a finished part.
    Type: Application
    Filed: August 13, 2021
    Publication date: October 20, 2022
    Inventors: Stephen T. CONNOR, Matthew MCKAY
  • Patent number: 11422532
    Abstract: A method for facilitating part fabrication, such as by automated toolpath generation, can include one or more of: receiving a virtual part; modifying the virtual part; and/or determining toolpaths to fabricate the target part. The toolpaths preferably define an ordered series of additive and subtractive toolpaths, more preferably wherein the additive and subtractive toolpaths are interleaved, which can function to achieve high manufacturing efficiency and/or performance. The method can additionally or alternatively include: generating machine instructions based on the toolpaths; fabricating the target part based on the machine instructions; calibrating the fabrication system; and/or any other suitable elements.
    Type: Grant
    Filed: November 26, 2019
    Date of Patent: August 23, 2022
    Assignee: Mantle Inc.
    Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom