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USOO958629OB2 (12) United States Patent (10) Patent No.: US 9,586.290 B2 Buller et al. (45) Date of Patent: *Mar. 7, 2017 (54) SYSTEMS FOR THREE-DIMENSIONAL (58) Field of Classification Search PRINTING CPC B23K 26/123; B23K 26/032: B23K 26/0884 USPC ............ 219/121.63, 121.64, 121.83, 121.84, (71) Applicant: Velo3D, Inc., Santa Clara, CA (US) 219/121.85, 121.86, 74; 118/56, 57, 100, (72) Inventors: Benyamin Buller, Cupertino, CA (US); (Continued) Erel Milshtein, Cupertino, CA (US); Sherman Seelinger, San Jose, CA (US) (56) References Cited (73) Assignee. VELO3D, INC., Campbell, CA (US) U.S. PATENT DOCUMENTS 4,177,087 A 12, 1979 Hills et al. (*) Notice: Subject to any disclaimer, the term of this 4,863,538 A 9, 1989 Deckard patent is extended or adjusted under 35 (Continued) U.S.C. 154(b) by 0 days. This patent is Subject to a terminal dis FOREIGN PATENT DOCUMENTS claimer. CN 10339.2153. A 11 2013 CN 103611934. A 3, 2014 (21) Appl. No.: 15/085,884 (Continued) (22) Filed: Mar. 30, 2016 OTHER PUBLICATIONS (65) Prior Publication Data Adam, et al. Design for additive manufacturing—element transi US 2016/02O7109 A1 Jul. 21, 2016 tions and aggregated structures. CIRP Journal of Manufacturing Related U.S. Application Data Science and Technology. Nov. 2014; 7:20-28. (Continued) (63) Continuation of application No. 14/745,108, filed on Jun. 19, 2015, now Pat. No. 9,346,127. Primary Examiner — Phuong Nguyen (Continued) (74) Attorney, Agent, or Firm — Wilson Sonsini Goodrich & Rosati (51) Int. Cl. B23K9/00 (2006.01) (57) ABSTRACT B22F 3/05 (2006.01) The present disclosure provides three-dimensional (3D) (Continued) objects, 3D printing processes, as well as methods, appara (52) U.S. Cl. tuses and systems for the production of a 3D object. Meth CPC ............ B23K 26/346 (2015.10); B22F 3/105 ods, apparatuses and systems of the present disclosure may (2013.01); B22F 3/1055 (2013.01); B22F 3/24 reduce or eliminate the need for auxiliary supports. The (2013.01); B23K 10/027 (2013.01); B23K present disclosure provides three dimensional (3D) objects 15/002 (2013.01); B23K 15/0086 (2013.01); printed utilizing the printing processes, methods, appara B23K 15/0093 (2013.01); B23K 15/02 tuses and systems described herein. (2013.01); (Continued) 29 Claims, 28 Drawing Sheets 88. s I * 8. "NS. T. O in US 9,586.290 B2 Page 2 Related U.S. Application Data B29K 2105/251 (2013.01); C04B 2235/6026 (2013.01); Y02P 10/295 (2015.11) (58) Field of Classification Search (60) Provisional application No. 62/015,230, filed on Jun. USPC ........ 118/120, 300, 308, 310, 612; 419/2, 7, 20, 2014, provisional application No. 62/028,760, 41.9/36, 27, 54 filed on Jul. 24, 2014, provisional application No. See application file for complete search history. 62/063,867, filed on Oct. 14, 2014, provisional application No. 62/136,378, filed on Mar. 20, 2015, (56) References Cited provisional application No. 62/168,699, filed on May 29, 2015. U.S. PATENT DOCUMENTS 4,938,816 7, 1990 Beaman et al. (51) Int. C. 4,962.988 10, 1990 Swann B2.8B I/00 (2006.01) 5,088,047 2, 1992 Bynum B33 IO/00 (2015.01) 5,127,037 6, 1992 Bynum B33/30/00 (2015.01) 5,155,321 10, 1992 Grube et al. 5,156,697 10, 1992 Bourell et al. B33/50/02 (2015.01) 5,203,944 4, 1993 Prinz et al. B2.8B I7/00 (2006.01) 5,204,055 4, 1993 Sachs et al. B23K 26/12 (2014.01) 5,208.431 5, 1993 Uchiyama et al. B23K 26/34 (2014.01) 5,252,264 10, 1993 Forderhase et al. C22C 38/02 (2006.01) 5.255.057 10, 1993 Stelter et al. 5,286,573 2, 1994 Prinz et al. C22C 38/44 (2006.01) 5,296,062 3, 1994 Bourell et al. C22C 38/58 (2006.01) 5,342,919 8, 1994 Dickens, Jr. et al. C04B 35/64 (2006.01) 5,352.405 10, 1994 Beaman et al. B33/40/00 (2015.01) 5,387,380 2, 1995 Cima ............... BOSC 19.04 B33Y 70/00 (2015.01) 264/109 5,393,482 2, 1995 Benda et al. B23K IOMO2 (2006.01) 5.430,666 7, 1995 DeAngelis et al. B23K I5/00 (2006.01) 5,460,758 10, 1995 Langer et al. B23K 26/I6 (2006.01) 5,508,489 4, 1996 Benda et al. B23K 26/32 (2014.01) 5,527,877 6, 1996 Dickens, Jr. et al. B29C 67/00 (2006.01) 5,534,104 T/1996 Langer et al. 5,536.467 T/1996 Reichle et al. B23K 26/22 (2006.01) 5,582,876 12, 1996 Langer et al. C22C 38/00 (2006.01) 5,593,531 1/1997 Penn C04B 3.5/52 (2006.01) 5,594,652 1/1997 Penn et al. C04B 3.5/56 (2006.01) 5,647,931 7/1997 Retallick et al. C04B 3.5/565 (2006.01) 5,648,450 7/1997 Dickens, Jr. et al. 5,658.412 8, 1997 Retallick et al. B33/80/00 (2015.01) 5,665,401 9, 1997 Serbin et al. B22F 3/24 (2006.01) 5,730,925 3, 1998 Mattes et al. B23K I5/02 (2006.01) 5,733,497 3, 1998 McAlea et al. B23K 26/08 (2014.01) 5,745,834 4, 1998 Bampton et al. 5,749,041 5, 1998 Lakshminarayan et al. B22F 7/00 (2006.01) 5,753,171 5, 1998 Serbin et al. B29K 10.5/OO (2006.01) 5,753,274 5, 1998 Wilkening et al. (52) U.S. C. 5,786,562 7, 1998 Larson CPC ........ B23K 26/0853 (2013.01); B23K 26/123 5,818,718 10, 1998 Thomas et al. 5,832,415 11, 1998 Wilkening et al. (2013.01); B23K 26/144 (2015.10); B23K 5,876,767 3, 1999 Mattes et al. 26/16 (2013.01); B23K 26/22 (2013.01); B23K 5,904,890 5, 1999 Lohner et al. 26/32 (2013.01); B23K 26/342 (2015.10); 5,908,569 6, 1999 Wilkening et al. B23K 26/345 (2013.01); B23K 26/70 5,932,059 8, 1999 Langer et al. (2015.10); B23K 26/702 (2015.10); B28B 6,042,774 3, 2000 Wilkening et al. 6,066,285 5/2000 Kumar I/001 (2013.01); B28B 17/0072 (2013.01); 6,085,122 T/2000 Manning B28B 17/0081 (2013.01); B29C 67/0077 6,126.276 10, 2000 Davis et al. (2013.01); B29C 67/0085 (2013.01); B29C 6,136,257 10, 2000 Graf et al. 67/0088 (2013.01); B29C 67/0092 (2013.01); 6,143,378 11/2000 Harwell et al. 6,151,345 11/2000 Gray B29C 67/0096 (2013.01); B33 Y 10/00 6,175,422 B1 ck 1, 2001 Penn ................ B29C 67,0059 (2014. 12); B33 Y30/00 (2014.12); B33 Y40/00 345/419 (2014.12); B33Y50/02 (2014.12); B33Y 70/00 6,206,672 3, 2001 Grenda (2014. 12); B33 Y 80/00 (2014.12); C04B 6,215,093 4, 2001 Meiners et al. 35/522 (2013.01); C04B 35/565 (2013.01); 6,251,488 6, 2001 Miller et al. 6,261,077 T/2001 Bishop et al. C04B 35/5626 (2013.01); C04B 35/64 6,268,584 T/2001 Keicher et al. (2013.01); C22C38/00 (2013.01); C22C38/02 6,336,480 1, 2002 Gaylo et al. (2013.01); C22C 38/44 (2013.01); C22C38/58 6,376,148 4, 2002 Liu et al. (2013.01); B22F 7700 (2013.01); B22F 6,391,251 5/2002 Keicher et al. 2003/1056 (2013.01); B22F 2003/1057 6,483,596 11/2002 Philippi et al. 6,531,086 3, 2003 Larsson (2013.01); B22F 2003/1058 (2013.01); B22F 6,554,600 4/2003 Hofmann et al. 2003/1059 (2013.01); B22F 2003/248 6,636,676 10, 2003 Renn (2013.01); B22F 2998/10 (2013.01); B23K 6,656.409 12, 2003 Keicher et al. 2203/50 (2015.10); B23K 2203/52 (2015.10); 6,656.410 12, 2003 Hull et al. US 9,586.290 B2 Page 3 (56) References Cited 8,132,744 B2 3/2012 Rennet al. 8,137,739 B2 3/2012 Philippi et al. 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