Notice of Pre-AIA or AIA Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
DETAILED ACTION
Status of Claims
Claims 21-40 are pending. Claims 21-30 and 37-40 are the subject of this NON-FINAL Office Action.
Election/Restrictions
Applicant’s election without traverse of Group I (claims 21-30 and 37-40) and the species of resin support shared component, resin support speed as a parameter and control system of claim 27 in the reply filed on 11/26/2025 is acknowledged. Upon further consideration, the species elections are withdrawn. Claims 31-36 are withdrawn as directed to non-election invention.
Double Patenting- Obvious Type
The nonstatutory double patenting rejection is based on a judicially created doctrine grounded in public policy (a policy reflected in the statute) so as to prevent the unjustified or improper timewise extension of the “right to exclude” granted by a patent and to prevent possible harassment by multiple assignees. A nonstatutory obviousness-type double patenting rejection is appropriate where the conflicting claims are not identical, but at least one examined application claim is not patentably distinct from the reference claim(s) because the examined application claim is either anticipated by, or would have been obvious over, the reference claim(s). See, e.g., In re Berg, 140 F.3d 1428, 46 USPQ2d 1226 (Fed. Cir. 1998); In re Goodman, 11 F.3d 1046, 29 USPQ2d 2010 (Fed. Cir. 1993); In re Longi, 759 F.2d 887, 225 USPQ 645 (Fed. Cir. 1985); In re Van Ornum, 686 F.2d 937, 214 USPQ 761 (CCPA 1982); In re Vogel, 422 F.2d 438, 164 USPQ 619 (CCPA 1970); and In re Thorington, 418 F.2d 528, 163 USPQ 644 (CCPA 1969).
A timely filed terminal disclaimer in compliance with 37 CFR 1.321(c) or 1.321(d) may be used to overcome an actual or provisional rejection based on a nonstatutory double patenting ground provided the conflicting application or patent either is shown to be commonly owned with this application, or claims an invention made as a result of activities undertaken within the scope of a joint research agreement.
Effective January 1, 1994, a registered attorney or agent of record may sign a terminal disclaimer. A terminal disclaimer signed by the assignee must fully comply with 37 CFR 3.73(b).
Instant claims 21-30 and 37-40 are rejected on the ground of nonstatutory obviousness-type double patenting as being unpatentable over conflicting claims 1-20 of U.S. 11813799.
The instant claims are obvious over the conflicting claims because the conflicting claims anticipate the instant by teaching
8. An additive manufacturing apparatus comprising:
a first print module including a first radiant energy device and a first stage configured to hold a first component;
a second print module including a second radiant energy device and a second stage configured to hold a second component, wherein the first print module and the second print module are configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device; and
a control system configured to translate the resin support based on a condition of the first print module and the second print module through the first print module and the second print module.
As is clear from conflicting claim 8, the conflicting claims teach an apparatus that falls within the instant claimed apparatus because the conflicting claims teach a resin support shared by the first print module and the second print module (“wherein the first print module and the second print module are configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device”).
Instant claims 21-30 and 37-40 are rejected on the ground of nonstatutory obviousness-type double patenting as being unpatentable over conflicting claims 1-20 of U.S. 11813799.
The instant claims are obvious over the conflicting claims because the conflicting claims anticipate the instant by teaching
8. An additive manufacturing apparatus comprising:
a first print module including a first radiant energy device and a first stage configured to hold a first component;
a second print module including a second radiant energy device and a second stage configured to hold a second component, wherein the first print module and the second print module are configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device; and
a control system configured to translate the resin support based on a condition of the first print module and the second print module through the first print module and the second print module.
As is clear from conflicting claim 8, the conflicting claims teach an apparatus that falls within the instant claimed apparatus because the conflicting claims teach a resin support shared by the first print module and the second print module (“wherein the first print module and the second print module are configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device”); and a “condition” is indistinguishable from a “parameter.”
Instant claims 21-30 and 37-40 are rejected on the ground of nonstatutory obviousness-type double patenting as being unpatentable over conflicting claims 1-35 of U.S. 11179891.
The instant claims are obvious over the conflicting claims because the conflicting claims anticipate the instant by teaching
12. A method for producing a component layer-by-layer, comprising:
providing a tape casting additive manufacturing machine including:
a resin support comprising a tape or a foil supported by a support plate, the resin support comprising at least a portion which is transparent, wherein the resin support defines a build surface;
a material depositor operable to deposit a resin which is radiant-energy-curable onto the build surface; and
at least two build stations, each build station including:
a stage positioned above the build surface and configured to hold a stacked arrangement of one or more cured layers of a radiant-energy-curable resin; and
one or more actuators operable to move the stage; and
at least one radiant energy apparatus positioned below the stage, and operable to generate and project radiant energy in a predetermined pattern;
executing a build cycle, including the steps of:
depositing on the build surface the resin;
positioning the stages relative to the build surface so as to define a layer increment in the resin on the build surface;
selectively curing the resin on the build surface using an application of radiant energy in a specific pattern so as to define the geometry of a cross-sectional layer of a component for each of the stages;
moving the build surface and the stages relatively apart so as to separate the component from the build surface; and
repeating the cycle, for a plurality of layers, until the components are complete.
22. The method of claim 12 wherein, between layers of the build cycle, the resin support is advanced to provide uncured resin to each of the at least two build stations.
23. The method of claim 22 wherein, between layers of the build cycle, the resin support is advanced to move uncured resin which was previously located between the at least two build stations underneath one or more of the at least two build stations.
25. A tape casting additive manufacturing machine, comprising:
two or more resin supports, each resin support comprising a tape or a foil supported by a support plate, each resin support comprising at least a portion which is transparent, wherein each resin support defines a build surface;
a material depositor operable to deposit a resin which is radiant-energy-curable onto the resin supports;
at least two build stations for each resin support, each build station including:
a stage positioned above the build surface and configured to hold a stacked arrangement of one or more cured layers of the resin;
one or more actuators operable to move the stage; and
a radiant energy apparatus disposed below the stages and operable to generate and project radiant energy in a predetermined pattern; and
means for delivering radiant energy from the radiant energy apparatus to each of the build stations.
30. A method for producing a component layer-by-layer, comprising:
providing a tape casting additive manufacturing machine including:
two or more resin supports, each resin support comprising a tape or a foil supported by a support plate, each resin support comprising at least a portion which is transparent, wherein each resin support defines a build surface;
a material depositor operable to deposit a resin which is radiant energy curable onto the build surface;
at least two build stations for each resin support, each build station including:
a stage positioned above the build surface and configured to hold a stacked arrangement of one or more cured layers of a radiant-energy-curable resin;
one or more actuators operable to move the stage and the build surface;
a radiant energy apparatus disposed below the stages and operable to generate and project radiant energy in a predetermined pattern; and
means for delivering radiant energy from the radiant energy apparatus to each of the build stations;
executing a build cycle, including the steps of:
depositing on the build surfaces the resin;
positioning each of the stages relative to the corresponding build surfaces so as to define a layer increment in the resin on the build surface;
selectively curing the resin on the build surface using an application of radiant energy in a specific pattern so as to define the geometry of a cross-sectional layer of a component for each of the stages;
moving the build surfaces and the stages relatively apart so as to separate the components from the build surfaces; and
repeating the cycle, for a plurality of layers, until the components are complete.
As is clear from conflicting claims, the conflicting claims teach an apparatus that falls within the instant claimed apparatus because the conflicting claims teach a resin support shared by the first print module and the second print module (“at least two build stations for each resin support”); and the resin support is shared between the build stations (“at least two build stations for each resin support”), then moved by controlling the resin support based on build cycle parameters (“22. The method of claim 12 wherein, between layers of the build cycle, the resin support is advanced to provide uncured resin to each of the at least two build stations. 23. The method of claim 22 wherein, between layers of the build cycle, the resin support is advanced to move uncured resin which was previously located between the at least two build stations underneath one or more of the at least two build stations.”).
Instant claims 21-30 and 37-40 are rejected on the ground of nonstatutory obviousness-type double patenting as being unpatentable over conflicting claims 1-20 of U.S. 11865780.
The instant claims are obvious over the conflicting claims because the conflicting claims anticipate the instant by teaching
1. An additive manufacturing apparatus comprising:
a feed module configured to operably couple with a first end portion of a foil;
a take-up module configured to operably couple with a second end portion of a foil;
at least one stage configured to hold one or more cured layers of a resin that form a component;
a radiant energy device positioned opposite to the at least one stage, the radiant energy device operable to generate and project radiant energy in a predetermined pattern;
an actuator configured to change a relative position of the at least one stage and the foil; and
an accumulator positioned between the feed module and the take-up module, the accumulator comprising:
a cavity defined by an accumulator housing;
a first guide positioned upstream of the cavity and downstream of the stage; and
a second guide positioned downstream of the cavity and downstream of the stage,
wherein the accumulator is configured to retain an intermediate portion of the foil within the cavity to allow a first portion of the foil upstream of the accumulator to move at a first speed and a second portion of the foil downstream of the accumulator to move at a second speed during a defined time period.
2. The additive manufacturing apparatus of claim 1, further comprising:
a reclamation system configured to remove at least a portion of the resin from the foil.
3. The additive manufacturing apparatus of claim 1, wherein the accumulator is configured to allow the first portion of the foil upstream of the accumulator to move intermittently while the second portion of the foil downstream of the accumulator to move continuously.
4. The additive manufacturing apparatus of claim 1, further comprising:
a material retention assembly within the accumulator.
5. The additive manufacturing apparatus of claim 4, wherein the material retention assembly includes a pneumatic actuation zone that is configured to selectively interact with the foil by producing a force on a first side of the foil, the first side of the foil being opposite the resin.
6. The additive manufacturing apparatus of claim 4, wherein the material retention assembly includes at least one retaining roller within a cavity defined by the accumulator.
7. The additive manufacturing apparatus of claim 1, further comprising:
a sensor configured to detect a length of the foil within the accumulator.
8. The additive manufacturing apparatus of claim 1, further comprising:
a computing system operably coupled with a detection system, the computing system configured to determine a speed of the second portion of the foil downstream of the accumulator based on an amount of the foil within the cavity.
9. The additive manufacturing apparatus of claim 1,
wherein at least one of the first guide and the second guide includes at least one roller or at least one pneumatic device configured to contact the foil externally from a cavity of the accumulator.
10. The additive manufacturing apparatus of claim 1, wherein the at least one stage includes a plurality of stages in parallel, and wherein each of the plurality of stages are positioned between a material depositor and the accumulator.
As is clear from conflicting claims, the conflicting claims teach an apparatus that falls within the instant claimed apparatus because the conflicting claims teach a resin support shared by the first print module and the second print module (“wherein the at least one stage includes a plurality of stages in parallel, and wherein each of the plurality of stages are positioned between a material depositor and the accumulator”); then moved by controlling the resin support based on parameters (“a computing system operably coupled with a detection system, the computing system configured to determine a speed of the second portion of the foil downstream of the accumulator based on an amount of the foil within the cavity”).
Instant claims 21-30 and 37-40 are rejected on the ground of nonstatutory obviousness-type double patenting as being unpatentable over conflicting claims 1-14 of U.S. 12434436.
The instant claims are obvious over the conflicting claims because the conflicting claims anticipate the instant by teaching
1. An additive manufacturing apparatus comprising:
a feed module configured to operably couple with a first end portion of a foil;
a take-up module configured to operably couple with a second end portion of the foil;
at least one stage configured to hold one or more cured layers of a resin that form a component;
an accumulator positioned between the feed module and the take-up module, the accumulator configured to retain an intermediate portion of the foil to allow a first portion of the foil upstream of the accumulator to move at a first speed and a second portion of the foil downstream of the accumulator to move at a second speed during a defined time period; and
a detection system configured to provide data related to one or more conditions of the accumulator or the foil within the accumulator.
3. The additive manufacturing apparatus of claim 1, further comprising:
a computing system operably coupled with the detection system, the computing system configured to determine one or more conditions of the accumulator or the foil within the accumulator based on the data.
4. The additive manufacturing apparatus of claim 1, wherein the one or more conditions includes a length of the foil within the accumulator, a distance from a lowermost portion of the foil above a bottom portion of a cavity of the accumulator, an amount of the foil within the cavity of the accumulator, a change in the amount of the foil within the accumulator, or a speed at which the foil enters and exits the cavity.
As is clear from conflicting claims, the conflicting claims teach an apparatus that falls within the instant claimed apparatus because the conflicting claims teach a resin support shared by the first print module and the second print module (“at least one stage” encompasses two or more stages; foil shared between them); then moved by controlling the resin support based on parameters (“a detection system configured to provide data related to one or more conditions of the accumulator or the foil within the accumulator”).
Prior Art
The Examiner cannot find prior art that teaches or suggests multiple resin print modules with a shared resin support (e.g. tape, foil, etc.) operably coupled with the first print module and the second print module; and a control system configured to control the first print module, the second print module, and the shared resin support based on one or more parameters that define a building of the first additively-manufactured component or the second additively-manufactured component. Claim 21 explicitly recite that the shared component is a resin support: “a second print module including a second radiant energy device and a second stage configured to hold a second additively-manufactured component, wherein the first print module and the second print module are configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device.” Resin supports are well-known in the SLA art (e.g. WO 0140866; US 20120195994; WO 2018226164; US20160185045). In fact, the closest prior art (US 20200198224) teaches a first build surface 26 and second build surface 126, but the foil 22 is only used on the first build surface 26:
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The Examiner cannot find a suggestion in the art to share a resin support between a first SLA print module (“a first print module including a first radiant energy device and a first stage configured to hold a first additively-manufactured component”) and second SLA print module (“a second print module including a second radiant energy device and a second stage
configured to hold a second additively-manufactured component”).
Conclusion
No claims are allowed.
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/YUNG-SHENG M TSUI/ Primary Examiner, Art Unit 1743