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).
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Patent number: 12257659Abstract: 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: GrantFiled: September 29, 2021Date of Patent: March 25, 2025Assignee: MANTLE INC.Inventors: Stephen T. Connor, Fabio Zurcher, Brad Eaton, Matthew McKay
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Publication number: 20250050588Abstract: 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: ApplicationFiled: August 9, 2024Publication date: February 13, 2025Applicant: MANTLEInventors: Stephen T. Connor, Michael A. Kottman
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Publication number: 20250026939Abstract: 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: ApplicationFiled: October 3, 2024Publication date: January 23, 2025Applicant: MANTLE INC.Inventors: Stephen T. CONNOR, James R. GROVES, Theodore C. SOROM
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Patent number: 12139638Abstract: 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: GrantFiled: September 18, 2018Date of Patent: November 12, 2024Assignee: MANTLE INC.Inventors: Stephen T. Connor, James R. Groves, Theodore C. Sorom
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Publication number: 20240319710Abstract: 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: ApplicationFiled: June 7, 2024Publication date: September 26, 2024Applicant: Mantle Inc.Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore C. Sorom
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Patent number: 12032356Abstract: 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: GrantFiled: April 19, 2023Date of Patent: July 9, 2024Assignee: Mantle Inc.Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom
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Publication number: 20240208136Abstract: 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: ApplicationFiled: January 26, 2024Publication date: June 27, 2024Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
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Patent number: 11919224Abstract: 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: GrantFiled: December 6, 2022Date of Patent: March 5, 2024Assignee: Mantle Inc.Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
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Publication number: 20240042697Abstract: 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: ApplicationFiled: August 8, 2022Publication date: February 8, 2024Applicant: MANTLE INC.Inventors: Stephen T. Connor, Nilesh Dixit, Ivan Ionov
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Patent number: 11813788Abstract: 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: GrantFiled: June 28, 2022Date of Patent: November 14, 2023Assignee: Mantle Inc.Inventors: Stephen T. Connor, Theodore C Sorom, James R. Groves
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Patent number: 11761706Abstract: 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: GrantFiled: March 14, 2022Date of Patent: September 19, 2023Assignee: Mantle Inc.Inventors: Stephen T. Connor, Fabio Zurcher, Thale Smith
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Publication number: 20230251626Abstract: 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: ApplicationFiled: April 19, 2023Publication date: August 10, 2023Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom
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Patent number: 11662711Abstract: 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: GrantFiled: July 12, 2022Date of Patent: May 30, 2023Assignee: Mantle Inc.Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom
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Publication number: 20230104107Abstract: 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: ApplicationFiled: December 6, 2022Publication date: April 6, 2023Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
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Publication number: 20230037565Abstract: 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: ApplicationFiled: October 21, 2022Publication date: February 9, 2023Inventors: Stephen T. Connor, Fabio Zurcher, Thale Smith
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Publication number: 20230028908Abstract: 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: ApplicationFiled: September 30, 2022Publication date: January 26, 2023Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
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Publication number: 20220339703Abstract: 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: ApplicationFiled: June 28, 2022Publication date: October 27, 2022Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
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Publication number: 20220342385Abstract: 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: ApplicationFiled: July 12, 2022Publication date: October 27, 2022Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom
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Publication number: 20220331873Abstract: 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: ApplicationFiled: August 13, 2021Publication date: October 20, 2022Inventors: Stephen T. CONNOR, Matthew MCKAY
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Patent number: 11422532Abstract: 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: GrantFiled: November 26, 2019Date of Patent: August 23, 2022Assignee: Mantle Inc.Inventors: Stephen T. Connor, Alex S. Goldenberg, Jonathan Hsu, Benjamin D. Voiles, Theodore Charles Sorom