IP Library Granted Patent US 12686170
Granted Patent B2
US 12686170 · App. 18/926,770 · Granted Jul 21, 2026

Advanced manufacturing operational apparatus, system, and method

Inventor: Spencer Dominic Koroly (San Diego, CA)
Assignee: United States of America as represented by the Secretary of the Navy
B29C64/25B29C64/232B29C64/236B29C64/307B29C64/364B33Y10/00B33Y30/00B29C64/118
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Quick Facts
Patent No.
US 12686170
App. No.
18/926,770
Granted
Jul 21, 2026
Kind
B2
Abstract

An advanced manufacturing operational apparatus, system, and method. In some embodiments, a three-dimensional printer, comprising an outer enclosure; and a print chamber within the outer enclosure, further comprising: a spool mount fixed proximally to a bottom of the print chamber and a rear of the print chamber, a compact toolhead coupled to a linear rail, and further comprising an extruder motor, a filament applicator, and a linear motor, wherein the linear motor is mounted towards the rear of the print chamber and may be selectively positioned above the spool mount, a linear drive system abutting the outer enclosure along at least one axis, a frame structure comprising a rigid base plate coupled to a vertical pulley system, a controller, and a non-transitory storage medium capable of storing machine-readable instructions executable to cause the controller to: utilize the filament applicator to dispense a build material.

Claims (39)

1 . An enclosed three-dimensional printer, comprising:

an outer enclosure; and

a print chamber within the outer enclosure, further comprising:

a spool mount fixed proximally to a bottom of the print chamber and a rear of the print chamber,

a compact toolhead coupled to a linear rail, and further comprising an extruder motor, a filament applicator, and a linear motor, wherein the linear motor is mounted towards the rear of the print chamber and may be selectively positioned above the spool mount,

a linear drive system abutting the outer enclosure along at least one axis,

a frame structure comprising a rigid base plate coupled to a vertical pulley system configured to translate the compact toolhead along a vertical axis within the print chamber,

a controller, and

a non-transitory storage medium capable of storing machine-readable instructions executable to cause the controller to:

utilize the filament applicator to dispense a build material.

2 . The enclosed three-dimensional printer of claim 1 , wherein the outer enclosure is a ruggedized case.

3 . The enclosed three-dimensional printer of claim 1 , wherein the outer enclosure is designed to fit tightly within a commercial-off-the-shelf server rack.

4 . A method of additive manufacturing, the steps comprising:

providing an enclosed additive manufacturing system comprising an outer enclosure; and

a print chamber within the outer enclosure, further comprising a spool mount fixed proximally to a bottom of the print chamber and a rear of the print chamber,

a compact toolhead coupled to a linear rail,

and further comprising an extruder motor,

a filament applicator,

and a linear motor,

wherein the linear motor is mounted towards the rear of the print chamber and may be selectively positioned above the spool mount, a linear drive system abutting the outer enclosure along at least one axis,

a frame structure comprising a rigid base plate coupled to a vertical pulley system configured to translate the compact toolhead along a vertical axis within the print chamber,

a controller, a non-transitory storage medium capable of storing machine-readable instructions executable to cause the controller to utilize the filament applicator to dispense a build material;

heating the print chamber with heat radiated from the filament dispenser;

receiving instructions to build a three-dimensional object; and

printing the three-dimensional object within the print chamber of the enclosed additive manufacturing system.

5 . The method of additive manufacturing of claim 4 , wherein the outer enclosure is a ruggedized case.

6 . The method of additive manufacturing of claim 4 , wherein the outer enclosure is designed to fit tightly within a commercial-off-the-shelf server rack.

7 . A rack mountable additive manufacturing system, comprising:

an outer enclosure capable of mounting to a server rack; and

a print chamber within the outer enclosure designed to maximize volumetric efficiency, further comprising:

a spool mount fixed proximally to a bottom of the print chamber and a rear of the print chamber,

a compact toolhead coupled to a linear rail, and further comprising an extruder motor, a filament applicator, and a linear motor, wherein the linear motor is mounted towards the rear of the print chamber and may be selectively positioned above the spool mount,

a linear drive system abutting the outer enclosure along at least one axis,

a frame structure comprising a rigid base plate coupled to a vertical pulley system configured to translate the compact toolhead along a vertical axis within the print chamber,

a controller, and

a non-transitory storage medium capable of storing machine-readable instructions executable to cause the controller to:

utilize the filament applicator to dispense a build material.

8 . The rack mountable additive manufacturing system of claim 7 , wherein the outer enclosure is a ruggedized case.

9 . The rack mountable additive manufacturing system of claim 7 , further comprising: a control system configured to manage additive manufacturing processes.