Ric Fulop

Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.

Binder jetting techniques can be used to deposit and bind metallic particles or the like in a net shape for debinding and sintering into a final part. Where support structures are required to mitigate deformation of the object during the debinding and/or sintering, an interface layer may be formed between the support structures and portions of the object in order to avoid bonding of the support structure to the object during sintering.

La présente invention concerne des dispositifs, systèmes et procédés concernant l'impression tridimensionnelle, et plus particulièrement des techniques permettant de fabriquer des structures de support, des couches de rupture et similaires conçues pour être utilisées avec des matériaux de construction frittables.

Lit de poudre rempli couche par couche avec un matériau de construction en poudre contenant un liant activable. Le liant dans chaque nouvelle couche est activé localement selon un modèle tridimensionnel informatisé d'un objet pour fabriquer, couche par couche, une forme nette frittable de l'objet dans le lit de poudre. La forme nette frittable peut ensuite être retirée, déliée si approprié, et frittée en une pièce finale.

A three-dimensional printer uses a fused filament fabrication process to fabricate a net shape object from build materials that can be debound and sintered into a final part. In order to facilitate separation of the object from surrounding support structures, the three-dimensional printer is configured to deposit material between adjacent surfaces of the object and the support that inhibit bonding between adjacent surfaces of the support structure and the object during sintering.

A printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. A thermally compatible support structure may be formed to support regions of the object using a dissolvable bulk metallic glass.

A printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. The Seebeck effect can be employed to monitor a temperature difference between a build material and a nozzle that is extruding the build material based on voltage. The temperature difference can, in turn, be used to control operation of the printer or to determine an absolute temperature based on direct measurement of a temperature of the nozzle.

A printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. A nozzle cleaning fixture may be provided for the printer that is shaped to physically dislodge solidified build material and other contaminants from the nozzle. A robotic system for the printer can be used to maneuver the nozzle into engagement with the nozzle cleaning fixture for periodic cleaning, or in response to a diagnostic condition or the like indicating a… Show more

A printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. A nozzle cleaning fixture may be provided for the printer that is shaped to physically dislodge solidified build material and other contaminants from the nozzle. A robotic system for the printer can be used to maneuver the nozzle into engagement with the nozzle cleaning fixture for periodic cleaning, or in response to a diagnostic condition or the like indicating a clogged nozzle. Show less

A control loop for extrusion of a metallic build material such as bulk metallic glass measures a force required to extrude the build material, and uses this sensed parameter to estimate a temperature of the build material. The temperature, or a difference between the estimated temperature and a target temperature, can be used to speed or slow extrusion of the build material to control heat transfer from a heating system along the feedpath. This general control loop may be modified to account… Show more

A control loop for extrusion of a metallic build material such as bulk metallic glass measures a force required to extrude the build material, and uses this sensed parameter to estimate a temperature of the build material. The temperature, or a difference between the estimated temperature and a target temperature, can be used to speed or slow extrusion of the build material to control heat transfer from a heating system along the feedpath. This general control loop may be modified to account for other possible conditions such as nozzle clogging or the onset of crystallization. Show less

L'invention concerne diverses améliorations apportées à la fabrication additive, y compris des techniques pour adapter des processus de fabrication de filaments fusionnés afin de fabriquer des objets métalliques avec des matériaux de construction métalliques.

A printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. A plasma depassivation wash is applied during deposition to remove oxidation and improve interlayer bonding between successive layers of the metallic build material. Other techniques such as ultrasonic vibration, formation of energy directors, joule heating, and the like, may be used in combination to form a mechanically robust bond between layers.

A printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. One or more contact probes may be used to detect a height and/or position of a nozzle, e.g., to zero, center, or otherwise calibrate the nozzle prior to a print, or to determine a height relative to a deposited layer of build material during fabrication.

A printer fabricates an object from a computerized model using a fused filament fabrication process and a build material. One or more energy directors such as ridges are formed in an exposed surface of the deposited build material to provide regions of high, localized contact force that can improve interlayer bonding between successive layers of the build material. An ultrasonic vibrator can also usefully be incorporated into the printer to apply additional energy along these energy directors… Show more

A printer fabricates an object from a computerized model using a fused filament fabrication process and a build material. One or more energy directors such as ridges are formed in an exposed surface of the deposited build material to provide regions of high, localized contact force that can improve interlayer bonding between successive layers of the build material. An ultrasonic vibrator can also usefully be incorporated into the printer to apply additional energy along these energy directors during deposition of a subsequent layer. Show less

A printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. A build plate that receives the object during fabrication includes a coating of material with a low melt temperature, such as a low melt temperature solder. In particular, the material may be an alloy that can be solidified while receiving the object, and then heated into a liquid state to facilitate removal of the object after fabrication is complete at a… Show more

A printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. A build plate that receives the object during fabrication includes a coating of material with a low melt temperature, such as a low melt temperature solder. In particular, the material may be an alloy that can be solidified while receiving the object, and then heated into a liquid state to facilitate removal of the object after fabrication is complete at a temperature sufficiently low that the adjacent, fabricated object does not melt or deform. Show less

A class of metallic composites is described with advantageous bulk properties for additive fabrication. In particular, the composites described herein can be used in fused filament fabrication or any other extrusion or deposition-based three-dimensional printing process.

Une classe de composites métalliques présentant des propriétés globales avantageuse pour la fabrication additive est décrite. En particulier, les composites décrits ici peuvent être utilisés dans la fabrication de filaments fusionnés ou dans tout autre processus d'impression tridimensionnelle par dépôt ou extrusion.

In an aspect, a printer fabricates an object from a computerized model using a fused filament fabrication process and a metallic build material. An ultrasonic vibrator is incorporated into the printer to improve the printing process, e.g., by disrupting a passivation layer on the deposited material to improve interlayer bonding, and to prevent adhesion of the metallic build material to a nozzle and other printer components.

A printer fabricates an object from a computerized model using a fused filament fabrication process and a bulk metallic glass build material. By heating the bulk metallic glass at an elevated temperature in between an object and adjacent support structures, an interface layer can be interposed between the object and support where the bulk metallic glass becomes crystallized to create a more brittle interface that facilitates removal of the support structure from the object after fabrication.

Thermal parameters for an additive manufacturing process are estimated using computer modeling, and these thermal parameters are used to control the additive manufacturing process. For example, the thermal parameters may be estimated based on bulk material properties, object geometry, control signals to thermal components of a system, and so forth.

A lithium-ion battery is provided that has a fast charge and discharge rate capability and low rate of capacity fade during high rate cycling. The battery can exhibit low impedance growth and other properties allowing for its use in hybrid electric vehicle applications and other applications where high power and long battery life are important features.

The invention provides bipolar articles (e.g., batteries and capacitors) with new architectures and methods of making and using the same. Articles are provided with interpenetrating anode and cathode structures that allow for improved power density, and arbitrary form factors that allow for formation in substantially any desired shape. The articles are useful for embedding or integral formation in various electronic devices to provide more efficient use of space in the devices. The articles… Show more

The invention provides bipolar articles (e.g., batteries and capacitors) with new architectures and methods of making and using the same. Articles are provided with interpenetrating anode and cathode structures that allow for improved power density, and arbitrary form factors that allow for formation in substantially any desired shape. The articles are useful for embedding or integral formation in various electronic devices to provide more efficient use of space in the devices. The articles optionally include self-organizing bipolar structures. Show less

An energy delivery system includes at least one string of two or more energy delivery modules electrically coupled in series. Each energy delivery module includes one or more energy delivery devices for storing and delivering electrical current, and a module monitor for monitoring and controlling each of the energy delivery devices. Each string of energy delivery modules includes a string communication path accessible to each of the energy delivery modules, wherein the module monitor of each… Show more

An energy delivery system includes at least one string of two or more energy delivery modules electrically coupled in series. Each energy delivery module includes one or more energy delivery devices for storing and delivering electrical current, and a module monitor for monitoring and controlling each of the energy delivery devices. Each string of energy delivery modules includes a string communication path accessible to each of the energy delivery modules, wherein the module monitor of each energy delivery module is operable to communicate information associated with its energy delivery module through the string communication path. Each string also includes a string manager device for communicating with each module monitor in the string, through the string communication path. The energy delivery system also includes a system controller for communicating with each string manager device through a system communication path. Show less

A battery management system includes one or more lithium ion cells in electrical connection, each said cell comprising: first and second working electrodes and one or more reference electrodes, each reference electrode electronically isolated from the working electrodes and having a separate tab or current collector exiting the cell and providing an additional terminal for electrical measurement; and a battery management system comprising a battery state-of-charge monitor, said monitor being… Show more

A battery management system includes one or more lithium ion cells in electrical connection, each said cell comprising: first and second working electrodes and one or more reference electrodes, each reference electrode electronically isolated from the working electrodes and having a separate tab or current collector exiting the cell and providing an additional terminal for electrical measurement; and a battery management system comprising a battery state-of-charge monitor, said monitor being operable for receiving information relating to the potential difference of the working electrodes and the potential of one or more of the working electrodes versus the reference electrode. Show less

L'invention concerne un système de distribution d'énergie qui comprend au moins une chaîne de deux modules de distribution d'énergie ou plus, électriquement couplés en série. Chaque module de distribution d'énergie comprend un ou plusieurs dispositifs de distribution d'énergie pour stocker et distribuer un courant électrique, et un moniteur de module pour surveiller et contrôler chacun des dispositifs de distribution d'énergie. Chaque chaîne de modules de distribution d'énergie comprend un… Show more

L'invention concerne un système de distribution d'énergie qui comprend au moins une chaîne de deux modules de distribution d'énergie ou plus, électriquement couplés en série. Chaque module de distribution d'énergie comprend un ou plusieurs dispositifs de distribution d'énergie pour stocker et distribuer un courant électrique, et un moniteur de module pour surveiller et contrôler chacun des dispositifs de distribution d'énergie. Chaque chaîne de modules de distribution d'énergie comprend un trajet de communication en chaîne accessible à chacun des modules de distribution d'énergie, dans lequel le moniteur de module de chaque module de distribution d'énergie est actionnable pour communiquer des informations associées à son module de distribution d'énergie par l'intermédiaire du trajet de communication en chaîne. Chaque chaîne comprend également un dispositif de gestion de chaîne permettant de communiquer avec chaque moniteur de module dans la chaîne par l'intermédiaire du trajet de communication en chaîne. Le système de distribution d'énergie comprend également un contrôleur de système permettant de communiquer avec chaque dispositif de gestion de chaîne par l'intermédiaire d'un trajet de communication de système. Show less

Un système de gestion de batterie comprend une ou plusieurs piles au lithium reliées électriquement, chaque pile comprenant : une première et une seconde électrode à étudier et une ou plusieurs électrodes de référence, chaque électrode de référence étant électroniquement isolée des électrodes à étudier et ayant une languette ou un collecteur de courant séparé(e) qui sort de la pile et offrant une borne supplémentaire pour la mesure électrique ; et un système de gestion de batterie qui comprend… Show more

Un système de gestion de batterie comprend une ou plusieurs piles au lithium reliées électriquement, chaque pile comprenant : une première et une seconde électrode à étudier et une ou plusieurs électrodes de référence, chaque électrode de référence étant électroniquement isolée des électrodes à étudier et ayant une languette ou un collecteur de courant séparé(e) qui sort de la pile et offrant une borne supplémentaire pour la mesure électrique ; et un système de gestion de batterie qui comprend un dispositif de surveillance d'état de charge de la batterie, ledit dispositif de surveillance pouvant recevoir des informations relatives à la différence de potentiel des électrodes à étudier et au potentiel d'une ou plusieurs des électrodes à étudier par rapport à l'électrode de référence. Show less

Batterie ion-lithium à potentiel de taux de charge/décharge élevé et à faible taux de perte de capacité durant des cycles à rythmes importants. La batterie est capable de présenter une faible croissance d'impédance et d'autres propriétés, ce qui permet de l'utiliser dans des applications de véhicules électriques hybrides et dans d'autres applications pour lesquelles le niveau élevé de la puissance et la longueur de la durée de vie sont des critères importants.

An energy delivery system includes at least one string of two or more energy delivery modules electrically coupled in series. Each energy delivery module includes one or more energy delivery devices for storing and delivering electrical current, and a module monitor for monitoring and controlling each of the energy delivery devices. Each string of energy delivery modules includes a string communication path accessible to each of the energy delivery modules, wherein the module monitor of each… Show more

An energy delivery system includes at least one string of two or more energy delivery modules electrically coupled in series. Each energy delivery module includes one or more energy delivery devices for storing and delivering electrical current, and a module monitor for monitoring and controlling each of the energy delivery devices. Each string of energy delivery modules includes a string communication path accessible to each of the energy delivery modules, wherein the module monitor of each energy delivery module is operable to communicate information associated with its energy delivery module through the string communication path. Each string also includes a string manager device for communicating with each module monitor in the string, through the string communication path. The energy delivery system also includes a system controller for communicating with each string manager device through a system communication path. Show less

Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.

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