IP Library Granted Patent US 11,117,313
Granted Patent B2
US 11,117,313 · App. 17/021,730 · Granted Sep 14, 2021

Near net shape additive manufacturing

Inventors: Kenneth J. Susnjara (Birdseye, IN); Brian S. Smiddy (Newburgh, IN); John Fuquay (Boonville, IN)
Assignee: Thermwood Corporation
B29C64/118B29C64/188B29C64/209B29C64/245B29C64/25B33Y10/00B33Y30/00B33Y40/20
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Quick Facts
Patent No.
US 11,117,313
App. No.
17/021,730
Granted
Sep 14, 2021
Kind
B2
Abstract

An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.

Claims (31)

1. An additive manufacturing method, comprising:

supporting an applicator with a fixed support structure;

depositing a first layer of thermoplastic material on a vertically-extending surface with the applicator and while moving the applicator in a first horizontal direction;

moving the vertically-extending surface with the deposited thermoplastic material in a second horizontal direction; and

depositing one or more additional layers of thermoplastic material on the first layer of thermoplastic material.

2. The additive manufacturing method of claim 1 , wherein the first horizontal direction is orthogonal to the second horizontal direction.

3. The additive manufacturing method of claim 1 , wherein the applicator is supported by the fixed support structure, a first vertically-extending support, and a second vertically-extending support.

4. The additive manufacturing method of claim 1 , wherein depositing the first layer of thermoplastic material is performed by extruding the thermoplastic material via a nozzle.

5. The additive manufacturing method of claim 1 , wherein moving the vertically-extending surface includes translating a work table with respect to a structure that supports the work table.

6. The additive manufacturing method of claim 5 , wherein the work table translates by sliding along a plurality of rollers.

7. The additive manufacturing method of claim 6 , wherein the fixed support structure extends above the work table.

8. The additive manufacturing method of claim 7 , further including moving the applicator in a vertical direction while the support structure remains fixed.

9. The additive manufacturing method of claim 1 , further including trimming a part that includes the first layer and the one or more additional layers with a trim head supported on support structure with the applicator.

10. An additive manufacturing method, comprising:

supporting an applicator on a support structure fixedly secured to a first vertically-extending support and a second vertically-extending support, the support structure extending across the first vertically-extending support and the second vertically-extending support;

depositing a first layer of thermoplastic material on a vertically-extending surface positioned below the support structure with the applicator, while moving the applicator in a first horizontal direction;

moving the vertically-extending surface in a second direction perpendicular to the first horizontal direction; and

depositing one or more additional layers of thermoplastic material on the first layer of thermoplastic material.

11. The additive manufacturing method of claim 10 , wherein the thermoplastic material is deposited from a nozzle in communication with an extruder secured to the support structure.

12. The additive manufacturing method of claim 11 , further including moving the extruder in the first horizontal direction with the applicator.

13. The additive manufacturing method of claim 10 , further including trimming a part that includes the first layer and the one or more additional layers with a trim head supported on the support structure with the applicator.

14. An additive manufacturing method, comprising:

supporting an applicator on a support member fixedly secured to a first vertically-extending support and a second vertically-extending support, the support member extending across the first vertically-extending support and the second vertically-extending support;

depositing a first layer of thermoplastic material on a work table positioned below the support member with a nozzle of the applicator and while moving the applicator in a first horizontal direction;

depositing one or more additional layers of thermoplastic material on the first layer of thermoplastic material; and

trimming a part that formed by the first layer and the one or more additional layers,

wherein the work table includes a vertically-extending surface that is movable in a direction away from the applicator during operation of the applicator or when trimming.

15. The additive manufacturing method of claim 14 , wherein the applicator is supported on a print carrier slidably connected to the support member.

16. The additive manufacturing method of claim 15 , wherein the applicator is supported on a print carrier and the trimming is performed by use of a trim carrier secured to the print carrier by a linking member.

17. The additive manufacturing method of claim 14 , wherein the support member extends across at least an entire width of the work table.

18. The additive manufacturing method of claim 17 , wherein the applicator is supported on a print carrier slidably secured on a rail of the support member that extends longer than a width of the work table.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 18, 2020
From: SUSNJARA, KENNETH J.; SMIDDY, BRIAN S.; FUQUAY, JOHN
To: THERMWOOD CORPORATION
Reel/Frame 053821/0084 →
Continuity (2)
Continuation 16692825 · Nov 22, 2019
Related Publication 20210154915A1 · May 27, 2021
Cited By (5)
US 12,304,139 US 12,304,140 US 12,304,141 US 12,420,475 US 12,679,022