How to Precisely Control Solid-State 3D Printing for Stronger Materials
This patent describes a system for precisely controlling solid-state additive manufacturing, allowing real-time adjustments to create specific material structures without melting, using continuous material feeds.
Original patent title: “Process control systems and methods using a solid-state additive manufacturing system and continuous feeding systems and structures”
This patent describes a system for precisely controlling solid-state additive manufacturing, allowing real-time adjustments to create specific material structures without melting, using continuous material feeds. Owned by Meld Manufacturing with 23 claims and 9 forward citations, and it is expected to expire in 2043.
Coverage
What does this patent actually cover?
The patent describes a system for controlling solid-state additive manufacturing, a type of 3D printing that joins materials without melting them. The system uses a feeding mechanism to supply solid material (like wire, powder, or pellets, as in claimsclaimsThe numbered statements at the end of a patent that legally define what the inventor owns.Read more → 25-30) to a tool. This tool then prints the material onto a workpiece while applying a downward force, causing the material to "plasticly deform" (claimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 24). A controller monitors and adjusts process variables, such as the downward force (using measurements like interface temperature or tooling torque, claims 32-33) and filler flow rate (claim 31). This precise control allows the system to create specific internal structures, like honeycomb or sandwich patterns (claim 36), within the printed material. For example, an engineer could program the system to build a part with a specific internal strength by continuously adjusting the pressure and material flow based on real-time sensor data.
The gap
What does this patent NOT cover?
- Additive manufacturing processes that involve melting the filler material (e.g., traditional FDM, laser powder bed fusion).
- Systems that do not continuously feed solid filler material to the tooling.
- Control systems that do not specifically adjust downward force based on a measured process variable from the tooling.
- Systems that do not aim to control the "microstructure" of the printed material.
- Additive manufacturing where the material is not "plasticly deformed" during printing.
These exclusions are unique to PatentBrief — derived from the actual claim language, not patent-office boilerplate.
Key facts
What made this novel
The noveltynoveltyThe requirement that an invention be different from anything publicly known before its priority date.Read more → lies in the real-time, closed-loop control system that precisely adjusts multiple process variables, like downward force and material flow, to achieve a specific internal microstructure in solid-state additive manufacturing. This allows for fine-tuning material properties during the build process, rather than relying on pre-set parameters.
The Patent Drawing
Schematic visualization of the patent's claim structure. Hand-drawn diagrams in progress for each landmark patent.
Where you've seen this
Real-world examples
MELD Manufacturing's solid-state additive manufacturing machines
Repairing large metal components
Building lightweight aerospace structures
Creating custom industrial tooling
Manufacturing parts from difficult-to-weld alloys
Why it matters
The bigger picture
Precisely controlling the printing process in solid-state additive manufacturing is crucial for creating parts with desired strength and properties. This technology can produce complex geometries and join dissimilar materials, which is valuable for industries needing high-performance components. The ability to control microstructure in real-time can lead to more reliable and optimized parts.
Filed
May 8, 2023
Market context
Who's building on this
Companies in this space
Meld Manufacturing, the assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more →, is actively developing and commercializing solid-state additive manufacturing systems. Other companies in the broader additive manufacturing space, particularly those focused on metal printing and repair, are also exploring advanced process control techniques.
Market impact
This patent contributes to the advancement of solid-state additive manufacturing, a technology that offers advantages over traditional welding and fusion-based 3D printing for certain applications. By enabling precise control over material properties and microstructure, it can expand the range of materials that can be processed and improve the performance and reliability of manufactured parts, potentially opening new markets for high-strength, lightweight components.
Claim 1 — Plain English
What this patent covers
The patent describes a system for controlling solid-state additive manufacturing, a type of 3D printing that joins materials without melting them. The system uses a feeding mechanism to supply solid material (like wire, powder, or pellets, as in claims 25-30) to a tool. This tool then prints the material onto a workpiece while applying a downward force, causing the material to "plasticly deform" (claim 24). A controller monitors and adjusts process variables, such as the downward force (using measurements like interface temperature or tooling torque, claims 32-33) and filler flow rate (claim 31). This precise control allows the system to create specific internal structures, like honeycomb or sandwich patterns (claim 36), within the printed material. For example, an engineer could program the system to build a part with a specific internal strength by continuously adjusting the pressure and material flow based on real-time sensor data.
The clever bit
The novelty lies in the real-time, closed-loop control system that precisely adjusts multiple process variables, like downward force and material flow, to achieve a specific internal microstructure in solid-state additive manufacturing. This allows for fine-tuning material properties during the build process, rather than relying on pre-set parameters.
What it does not cover
- Additive manufacturing processes that involve melting the filler material (e.g., traditional FDM, laser powder bed fusion).
- Systems that do not continuously feed solid filler material to the tooling.
- Control systems that do not specifically adjust downward force based on a measured process variable from the tooling.
- Systems that do not aim to control the "microstructure" of the printed material.
- Additive manufacturing where the material is not "plasticly deformed" during printing.
Patent timeline
Application submitted to the patent office
Patent enters public domain
PatentBrief Score
Impact Score
Early stage
Citation count
20/40
Early citations
Claim breadth
15/20
Broad claimsclaimsThe numbered statements at the end of a patent that legally define what the inventor owns.Read more →
Recency
0/20
Older than 20 years
Assignee scale
0/20
Independent or smaller assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more →
PatentBrief Impact Score — based on citation count, claim breadth, recency, and assignee scale. Not a legal assessment.
Heuristic Value Estimate
What this patent might be worth
$56K – $180K
Midpoint $112K · 16.7 yr remaining · industry ×0.9
Heuristic only — blends forward/backward citation counts, claim scope, time remaining, litigation history, and CPC-derived industry baseline. Real valuations need a professional appraisal.
Claim text not yet imported for this patent
The original legal language
Original claims
23 claims as filed with the patent office.
Concepts involved
Citations
Patent lineage
Cite this patent
Garguilo, C., Broach, A. T., Cox, C., Hardwick, N., & Lalande, F. How to Precisely Control Solid-State 3D Printing for Stronger Materials (U.S. Patent No. 20,240,109,245). U.S. Patent and Trademark Office. https://patentbrief.org/patent/us/20240109245/process-control-systems-and-methods-using-a-solid-state-additive-manufacturing-s
Auto-generated from the patent record. Double-check author order and the issue date against the official USPTO document before submitting.
Embed
Add this patent to your site
Drop this plain-English patent card into any blog post or article — free, no signup. It always links back to the full breakdown here.
<div data-patentlens-widget data-patent-number="US20240109245"></div> <script src="https://patentbrief.org/embed.js" async></script>
Stay in the loop
Get a weekly digest of new patents.
One email per week. No spam. Unsubscribe anytime.
Keep exploring
Related patents you should know
US 4683195 · 1987
How to Make Billions of Copies of a DNA Segment
This patent describes the Polymerase Chain Reaction (PCR), a method to rapidly create many copies of a specific piece of DNA or RNA, enabling its detection and analysis.
Cetus Corp
US 8697359 · 2014
How to Edit Genes in Human Cells Using an Engineered CRISPR System
This patent describes an engineered CRISPR-Cas9 system for precisely cutting DNA in eukaryotic cells to change how genes work, opening the door for gene editing in complex organisms.
Massachusetts Institute of Technology
US 7657849 · 2010
How the iPhone's Slide-to-Unlock Gesture Works
Apple's 2010 patent describes unlocking a device by dragging a specific graphical image across the touchscreen along a predefined path, a gesture that became iconic with the original iPhone.
Apple Inc
US 4733665 · 1988
How Doctors Implant a Permanent Stent Using a Balloon
This patent describes the method for placing a permanent, expandable wire mesh tube inside a blood vessel or other body tube using a balloon-tipped catheter to widen it and keep it open.
Expandable Grafts Partnership
US 4965188 · 1990
How to Make Many Copies of a DNA Piece with Heat
This patent describes the Polymerase Chain Reaction (PCR) method, a technique to make millions of copies of a specific DNA segment using a heat-resistant enzyme and repeated temperature changes.
Cetus Corp
US 4235871 · 1980
How to Encapsulate Active Materials in Lipid Bubbles Efficiently
This patent describes a method for trapping biologically active substances inside tiny, multi-layered fat bubbles called liposomes, using a specific water-in-oil emulsion and gel-forming process to improve how much material gets captured.
Individual
Semantically similar
You might also find these interesting
US 11311959 · 2022 · Meld Manufacturing
Building Metal Parts Without Melting: Solid-State 3D Printing System
US 12233456 · 2025
How to Improve 3D Printing Using Cold Spray Metal Deposition
US 11794927 · 2023 · Boeing Co
How Boeing 3D Prints Strong Lightweight Spacecraft Panels
US 5121329 · 1992 · Stratasys Inc
How Machines Build 3D Objects Layer by Layer from Melting Plastic
More to explore
More in Materials & Manufacturing
US 4575330 · 1986 · UVP Inc
How 3D Printers Build Objects Layer by Layer from Liquid
US 3953566 · 1976 · WL Gore and Associates Inc
Making Strong, Porous PTFE: The Gore-Tex Process
US 5121329 · 1992 · Stratasys Inc
How Machines Build 3D Objects Layer by Layer from Melting Plastic
US 3691140 · 1972
Sticky, Tiny Plastic Balls Made from Acrylates
New to patents?
Common Questions
Frequently Asked Questions
What does How to Precisely Control Solid-State 3D Printing for Stronger Materials cover?
This patent describes a system for precisely controlling solid-state additive manufacturing, allowing real-time adjustments to create specific material structures without melting, using continuous material feeds.
Who owns patent US 20240109245?
This patent is owned by Meld Manufacturing.
When does this patent expire?
This patent is expected to expire on May 8, 2043, when the invention enters the public domain.
What is patent US 20240109245 cited by?
This patent has been cited by 9 later patents that build on its ideas.
What problem does this patent solve?
Precisely controlling the printing process in solid-state additive manufacturing is crucial for creating parts with desired strength and properties. This technology can produce complex geometries and join dissimilar materials, which is valuable for industries needing high-performance components. The ability to control microstructure in real-time can lead to more reliable and optimized parts.
What does this patent NOT cover?
Additive manufacturing processes that involve melting the filler material (e.g., traditional FDM, laser powder bed fusion).
Same assignee
More from Meld Manufacturing
Patent monitoring