Patents by Inventor W. Ryan Powell
W. Ryan Powell 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: 20230330937Abstract: A method of cleaning residual resin from an additively manufactured object, the method including: producing by additive manufacturing at least one object on at least one carrier platform, each object including a light polymerized resin with a surface coating of viscous, unpolymerized residual resin; operatively connecting each object to a rotor; separating the residual resin from each object; and removing the at least one object from the rotor with the residual resin separated therefrom. The separating step may include: centrifugally separating the residual resin from each object by spinning the rotor with the at least object operatively connected thereto; and rotating (or tilting) each object about at least one axis during the spinning to enhance the centrifugally separating the residual resin from each object.Type: ApplicationFiled: April 11, 2023Publication date: October 19, 2023Inventors: Bob E. Feller, W. Ryan Powell, Mark O. Kaufman
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Patent number: 11731345Abstract: A method of producing multiple batches of objects by stereolithography, includes the steps of: (a) dispensing an initial or subsequent batch of dual cure resin into a stereolithography apparatus, the resin including a light polymerizable component and a heat polymerizable component; (b) producing an intermediate object by light polymerization of the resin in the apparatus, wherein the intermediate object retains excess resin on a surface thereof; then (c) separating excess resin from the intermediate object; (d) blending the excess resin with additional dual cure resin to produce a subsequent batch of dual cure resin; (e) repeating steps (a) through (c), and optionally repeating step (d), to produce additional object(s); and (f) baking the objects, together or separately, to produce multiple batches of objects.Type: GrantFiled: January 6, 2022Date of Patent: August 22, 2023Assignee: Carbon, Inc.Inventors: Courtney F. Converse, Allison Light, W. Ryan Powell, Mateusz Marek Wojtaszek
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Publication number: 20230027112Abstract: A method of cleaning residual resin from an additively manufactured object, includes: (a) enclosing an additively manufactured object in an inner chamber of a centrifugal separator, the additively manufactured object including a light polymerized resin with a surface coating of viscous, unpolymerized, residual resin; (b) flooding the chamber with a volatile organic solvent vapor without contacting liquid organic solvent to the object, the vapor present in an amount sufficient to reduce the viscosity of the residual resin; and (c) spinning the additively manufactured object in the chamber to centrifugally separate at least a first portion of the residual resin from the object.Type: ApplicationFiled: October 3, 2022Publication date: January 26, 2023Inventors: Bob E. Feller, W. Ryan Powell, Mark O. Kaufman
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Patent number: 11541600Abstract: A method of making an object by additive manufacturing includes: (a) providing an additive manufacturing apparatus including a light source; (b) providing a carrier platform having a substantially planar object adhesion surface, the adhesion surface having a plurality of elongate wash channels formed therein; (c) producing the object on the carrier platform adhesion surface with the additive manufacturing apparatus from a light polymerizable resin, the object having at least one internal cavity formed therein; then (d) washing the object on the carrier platform with a wash liquid under conditions in which the wash liquid reaches the at least one internal cavity through the wash channels; then (e) optionally, at least partially drying the object on the carrier platform by separating the same from the wash liquid, and then agitating the object on the carrier platform to drain excess wash liquid from the object; (f) optionally, further curing the object.Type: GrantFiled: March 19, 2019Date of Patent: January 3, 2023Assignee: Carbon, Inc.Inventors: R. Griffin Price, W. Ryan Powell, Yongqiang Li
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Publication number: 20220410480Abstract: A method of making a three-dimensional object from a polymerizable resin, the method comprising the steps of: (a) providing a carrier platform on which the three-dimensional object can be formed; (b) producing the three-dimensional object adhered to the carrier platform from the polymerizable resin by stereolithography, the object having residual resin on the surface thereof; (c) immersing the object in a wash liquid with the object remaining adhered to the carrier platform; (d) agitating (i) the object in said wash liquid (e.g., by spinning), (ii) the wash liquid with the object immersed therein (e.g., by sonication of the wash liquid), or (iii) both the object in the wash liquid and the wash liquid with the object immersed therein, to at least partially remove residual resin from the surface of the object; (e) separating the object from the wash liquid, with the object remaining adhered to the carrier platform, the object having residual wash liquid on the surface thereof; (f) agitating the object (e.g.Type: ApplicationFiled: September 2, 2022Publication date: December 29, 2022Inventors: Courtney F. Converse, W. Ryan Powell, Sherwood Forlee, David Eliot Scheinman, Scott Heines, Edwin James Sabathia, JR.
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Patent number: 11491725Abstract: A method of cleaning residual resin from an additively manufactured object, includes: (a) enclosing an additively manufactured object in an inner chamber of a centrifugal separator, the additively manufactured object including a light polymerized resin with a surface coating of viscous, unpolymerized, residual resin; (b) flooding the chamber with a volatile organic solvent vapor without contacting liquid organic solvent to the object, the vapor present in an amount sufficient to reduce the viscosity of the residual resin; and (c) spinning the additively manufactured object in the chamber to centrifugally separate at least a first portion of the residual resin from the object.Type: GrantFiled: April 13, 2022Date of Patent: November 8, 2022Assignee: Carbon, Inc.Inventors: Bob E. Feller, W. Ryan Powell, Mark O. Kaufman
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Patent number: 11478987Abstract: Method of making a three-dimensional object, comprising the steps of: (a) providing a carrier platform on which the three-dimensional object can be formed; (b) producing the three-dimensional object, (c) immersing the object in a wash liquid with the object remaining adhered to the carrier platform; (d) agitating (i) the object in said wash liquid, (ii) the wash liquid with the object immersed therein, or (iii) both the object and the wash liquid, to at least partially remove residual resin from the surface of the object; (e) separating the object from the wash liquid, with the object remaining adhered to the carrier platform, (f) agitating the object to at least partially remove residual wash liquid from the surface thereof; and (g) repeating steps (c) through (f) to remove additional polymerizable resin from the surface thereof, wherein steps (c) through (f) are carried out in the same vessel.Type: GrantFiled: November 29, 2017Date of Patent: October 25, 2022Assignee: Carbon, Inc.Inventors: Courtney F. Converse, W. Ryan Powell, Sherwood Forlee, David Eliot Scheinman, Scott Heines, Edwin James Sabathia, Jr.
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Publication number: 20220250312Abstract: A method of producing multiple batches of objects by stereolithography, includes the steps of: (a) dispensing an initial or subsequent batch of dual cure resin into a stereolithography apparatus, the resin including a light polymerizable component and a heat polymerizable component; (b) producing an intermediate object by light polymerization of the resin in the apparatus, wherein the intermediate object retains excess resin on a surface thereof; then (c) separating excess resin from the intermediate object; (d) blending the excess resin with additional dual cure resin to produce a subsequent batch of dual cure resin; (e) repeating steps (a) through (c), and optionally repeating step (d), to produce additional object(s); and (f) baking the objects, together or separately, to produce multiple batches of objects.Type: ApplicationFiled: January 6, 2022Publication date: August 11, 2022Inventors: Courtney F. Converse, Allison Light, W. Ryan Powell, Mateusz Marek Wojtaszek
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Publication number: 20220234296Abstract: A method of cleaning residual resin from an additively manufactured object, includes: (a) enclosing an additively manufactured object in an inner chamber of a centrifugal separator, the additively manufactured object including a light polymerized resin with a surface coating of viscous, unpolymerized, residual resin; (b) flooding the chamber with a volatile organic solvent vapor without contacting liquid organic solvent to the object, the vapor present in an amount sufficient to reduce the viscosity of the residual resin; and (c) spinning the additively manufactured object in the chamber to centrifugally separate at least a first portion of the residual resin from the object.Type: ApplicationFiled: April 13, 2022Publication date: July 28, 2022Inventors: Bob E. Feller, W. Ryan Powell, Mark O. Kaufman
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Publication number: 20220192307Abstract: A helmet liner includes: (a) an open lattice body portion comprised of a polymer, the body portion having opposite face portions and a circumferential side portion; (b) a helmet contact surface portion formed on one of the face portions; and (c) a skin contact portion formed on the other of the face portions, the skin contact portion configured with the lattice body portion so air can circulate through both the body portion and the skin contact portion.Type: ApplicationFiled: March 11, 2022Publication date: June 23, 2022Inventors: Allison Light, Ananda Day, Mohamed Imran Jameel, W. Ryan Powell
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Patent number: 11304471Abstract: A helmet liner includes: (a) an open lattice body portion comprised of a polymer, the body portion having opposite face portions and a circumferential side portion; (b) a helmet contact surface portion formed on one of the face portions; and (c) a skin contact portion formed on the other of the face portions, the skin contact portion configured with the lattice body portion so air can circulate through both the body portion and the skin contact portion.Type: GrantFiled: October 10, 2019Date of Patent: April 19, 2022Assignee: Carbon, Inc.Inventors: Allison Light, Ananda Day, Mohamed Imran Jameel, W. Ryan Powell
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Patent number: 11247389Abstract: A method of producing multiple batches of objects by stereolithography, includes the steps of: (a) dispensing an initial or subsequent batch of dual cure resin into a stereolithography apparatus (11), the resin including a light polymerizable component and a heat polymerizable component; (b) producing an intermediate object by light polymerization of the resin in the apparatus (12), wherein the intermediate object retains excess resin on a surface thereof; then (c) separating excess resin from the intermediate object (13); (d) blending the excess resin with additional dual cure resin to produce a subsequent batch of dual cure resin (15); (e) repeating steps (a) through (c), and optionally repeating step (d), to produce additional object(s); and (f) baking the objects, together or separately, to produce multiple batches of objects (14).Type: GrantFiled: April 22, 2019Date of Patent: February 15, 2022Assignee: Carbon, Inc.Inventors: Courtney F. Converse, Allison Light, W. Ryan Powell, Mateusz Marek Wojtaszek
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Publication number: 20210213675Abstract: A method of producing multiple batches of objects by stereolithography, includes the steps of: (a) dispensing an initial or subsequent batch of dual cure resin into a stereolithography apparatus (11), the resin including a light polymerizable component and a heat polymerizable component; (b) producing an intermediate object by light polymerization of the resin in the apparatus (12), wherein the intermediate object retains excess resin on a surface thereof; then (c) separating excess resin from the intermediate object (13); (d) blending the excess resin with additional dual cure resin to produce a subsequent batch of dual cure resin (15); (e) repeating steps (a) through (c), and optionally repeating step (d), to produce additional object(s); and (f) baking the objects, together or separately, to produce multiple batches of objects (14).Type: ApplicationFiled: April 22, 2019Publication date: July 15, 2021Inventors: Courtney F. Converse, Allison Light, W. Ryan Powell, Mateusz Marek Wojtaszek
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Publication number: 20200113267Abstract: A helmet liner includes: (a) an open lattice body portion comprised of a polymer, the body portion having opposite face portions and a circumferential side portion; (b) a helmet contact surface portion formed on one of the face portions; and (c) a skin contact portion formed on the other of the face portions, the skin contact portion configured with the lattice body portion so air can circulate through both the body portion and the skin contact portion.Type: ApplicationFiled: October 10, 2019Publication date: April 16, 2020Inventors: Allison Light, Ananda Day, Mohamed Imran Jameel, W. Ryan Powell
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Publication number: 20200078831Abstract: Method of making a three-dimensional object, comprising the steps of: (a) providing a carrier platform on which the three-dimensional object can be formed; (b) producing the three-dimensional object, (c) immersing the object in a wash liquid with the object remaining adhered to the carrier platform; (d) agitating (i) the object in said wash liquid, (ii) the wash liquid with the object immersed therein, or (iii) both the object and the wash liquid, to at least partially remove residual resin from the surface of the object; (e) separating the object from the wash liquid, with the object remaining adhered to the carrier platform, (f) agitating the object to at least partially remove residual wash liquid from the surface thereof; and (g) repeating steps (c) through (f) to remove additional polymerizable resin from the surface thereof, wherein steps (c) through (f) are carried out in the same vessel.Type: ApplicationFiled: November 29, 2017Publication date: March 12, 2020Inventors: Courtney F. CONVERSE, W. Ryan POWELL, Sherwood FORLEE, David EIiot SCHEINMAN, Scott HEINES, Edwin James SABATHIA
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Publication number: 20190291347Abstract: A method of making an object by additive manufacturing includes: (a) providing an additive manufacturing apparatus including a light source; (b) providing a carrier platform having a substantially planar object adhesion surface, the adhesion surface having a plurality of elongate wash channels formed therein; (c) producing the object on the carrier platform adhesion surface with the additive manufacturing apparatus from a light polymerizable resin, the object having at least one internal cavity formed therein; then (d) washing the object on the carrier platform with a wash liquid under conditions in which the wash liquid reaches the at least one internal cavity through the wash channels; then (e) optionally, at least partially drying the object on the carrier platform by separating the same from the wash liquid, and then agitating the object on the carrier platform to drain excess wash liquid from the object; (f) optionally, further curing the object.Type: ApplicationFiled: March 19, 2019Publication date: September 26, 2019Inventors: R. Griffin Price, W. Ryan Powell, Yongqiang Li