`Petition for Inter Partes Review of
`U.S. Patent No. 9,987,798
`
`
`UNITED STATES PATENT AND TRADEMARK OFFICE
`
`
`BEFORE THE PATENT TRIAL AND APPEAL BOARD
`
`
`MARKFORGED INC.,
`Petitioner,
`v.
`CONTINUOUS COMPOSITES, INC.,
`Patent Owner
`
`
`IPR2022-01218
`IPR2022-01220
`U.S. Patent No. 9,987,798
`Issue Date: June 5, 2018
`Title: METHOD AND APPARATUS FOR CONTINUOUS COMPOSITE THREE-
`DIMENSIONAL PRINTING
`
`DECLARATION OF DAVID ROSEN, PH.D. IN SUPPORT OF PETITION
`FOR INTER PARTES REVIEW OF U.S. PATENT NO. 10,744,798
`
`
`
`
`ACTIVE/117858922
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`
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`Page 1 of 237
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`Markforged Ex. 1002
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`TABLE OF CONTENTS
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`I.
`
`II.
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`Page i
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`QUALIFICATIONS ....................................................................................... 1
`A. Materials Considered ............................................................................ 4
`LEGAL PRINCIPLES .................................................................................... 5
`A.
`Prior Art ................................................................................................ 6
`B.
`Claim Construction .............................................................................. 6
`C. Anticipation .......................................................................................... 8
`D. Obviousness .......................................................................................... 9
`III. LEVEL OF ORDINARY SKILL IN THE ART .......................................... 10
`IV. THE ’798 PATENT ...................................................................................... 12
`A. Overview of the ’798 Patent ............................................................... 12
`B.
`Prosecution History ............................................................................ 19
`C.
`The Challenged Claims ...................................................................... 22
`V. APPLICATION OF THE PRIOR ART TO ASSERTED CLAIMS ........... 29
`A.
`Brief Summary of Prior Art ............................................................... 31
`1.
`Lipsker [Ex. 1006] ................................................................... 31
`2. Ma [Ex. 1007] .......................................................................... 37
`3.
`Crump [Ex. 1008] .................................................................... 44
`4.
`Nikzad [Ex. 1009] .................................................................... 47
`5. Wohrl [Ex. 1010] ..................................................................... 49
`6. Masters [Ex. 1011] ................................................................... 53
`B. Ground 1: Ma Renders Obvious Claims 1, 2, 6-11, 14, and 18 ......... 56
`1.
`Independent Claim 1 ................................................................ 56
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`1[pre]) ............................................................................ 56
`“directing a curable liquid material to a nozzle;”
`(Claim Element 1[a]) ..................................................... 57
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`TABLE OF CONTENTS
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`Page ii
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`c.
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`d.
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`e.
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`f.
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`b.
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`“directing a continuous strand material to the
`nozzle;” (Claim Element 1[b]) ...................................... 59
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 1[c]) .................................... 59
`“bonding an end point of the path of composite
`material to an anchor; and” (Claim Element 1[d]) ........ 60
`“moving the nozzle away from the anchor during
`discharging to pull the path of composite material
`out of the nozzle.” (Claim Element 1[e]) ...................... 62
`Claim 2 ..................................................................................... 63
`a.
`“wherein bonding the end point of the path of
`composite material to the anchor includes: placing
`the end point of the path of composite material on
`the anchor; and” (Claim Element 2[a]) ......................... 63
`“aiming a curing device at the path of composite
`material on the anchor.” (Claim Element 2[b]) ............ 64
`Claim 6: “wherein discharging from the nozzle the path
`of composite material includes discharging the path of
`composite material through a nozzle orifice having a
`diameter of about 2 mm.” ........................................................ 66
`Claim 7: “wherein the continuous strand material
`includes a plurality of strands arranged in at least one of a
`tow, a roving, and a weave.” .................................................... 68
`Claim 8: “wherein directing the curable liquid material to
`the nozzle includes directing a filler material at least
`partially coated in the curable liquid material to the
`nozzle.” .................................................................................... 69
`Claim 9: “wherein the filler material includes pieces of
`fibers.” ...................................................................................... 70
`Claim 10: “wherein the continuous strand material is
`hollow.” .................................................................................... 72
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`-ii-
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`2.
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`3.
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`4.
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`5.
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`6.
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`7.
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`TABLE OF CONTENTS
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`Page iii
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`b.
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`c.
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`Claim 11 ................................................................................... 73
`a.
`“curing a first portion of the path of composite
`material;” (Claim Element 11[a]) .................................. 73
`“overlapping the first portion of the path of
`composite material with a second portion of the
`path of composite material that is uncured; and”
`(Claim Element 11[b]) ................................................... 74
`“curing the second portion of the path of
`composite material while the first and second
`portions of the path of composite material are
`overlapped.” (Claim Element 11[c] ............................... 75
`Independent Claim 14 .............................................................. 76
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`14[pre]) .......................................................................... 76
`“directing a curable liquid material to a nozzle;”
`(Claim Element 14[a]) ................................................... 76
`“directing a continuous strand material to the
`nozzle;” (Claim Element 14[b]) .................................... 76
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 14[c]) .................................. 77
`“curing the curable liquid material in the path of
`composite material; and” (Claim Element 14[d]) ......... 77
`“moving the nozzle during discharging to create
`tension in the continuous strand material that
`remains after curing of the composite material.”
`(Claim Element 14[e]) ................................................... 77
`Independent Claim 18 .............................................................. 79
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`18[pre]) .......................................................................... 80
`-iii-
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`b.
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`c.
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`d.
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`e.
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`f.
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`8.
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`9.
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`10.
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`TABLE OF CONTENTS
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`Page iv
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`b.
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`c.
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`d.
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`e.
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`f.
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`“directing a curable liquid material to a nozzle;”
`(Claim Element 18[a]) ................................................... 80
`“directing a continuous strand material to the
`nozzle;” (Claim Element 18[b]) .................................... 80
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 18[c]) .................................. 80
`“adjusting a trajectory of the path of uncured
`composite material to a new location after
`discharge from the nozzle; and” (Claim Element
`18[d]) ............................................................................. 80
`“curing the curable liquid material in the path of
`uncured composite material at the new location
`after adjusting.” (Claim Element 18[e]) ........................ 82
`C. Ground 2: The Combination of Ma and Lipsker Renders
`Obvious Claims 3, 5, 12, 16, 17, and 19 ............................................ 82
`1.
`Claim 3: “wherein aiming the curing device includes
`aiming at least one UV light.”.................................................. 82
`Claim 5: “wherein aiming the at least one UV light
`includes aiming the at least one UV light from only a
`trailing side of the nozzle.” ...................................................... 86
`Claim 12: “wherein the overlapping includes wrapping
`the second portion of the path of composite material
`around the first portion of the path of composite
`material.” .................................................................................. 87
`Independent Claim 16 .............................................................. 93
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`16[pre]) .......................................................................... 93
`“directing a curable liquid material to a nozzle;”
`(Claim Element 16[a]) ................................................... 94
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`2.
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`3.
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`4.
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`b.
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`TABLE OF CONTENTS
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`Page v
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`c.
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`d.
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`“directing a continuous strand material to the
`nozzle;” (Claim Element 16[b]) .................................... 96
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 16[c]) .................................. 97
`“aiming a curing device at the path of discharged
`composite material to cure the curable liquid
`material;” (Claim Element 16[d]) .................................. 99
`“moving the nozzle during discharging to create
`the three-dimensional object; and” (Claim Element
`16[e]) ............................................................................ 100
`“moving the curing device together with the
`nozzle.” (Claim Element 16[f]) ................................... 101
`Independent Claim 17 ............................................................ 102
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`17[pre]) ........................................................................ 103
`“directing a curable liquid material to a nozzle;”
`(Claim Element 17[a]) ................................................. 103
`“directing a continuous strand material to the
`nozzle;” (Claim Element 17[b]) .................................. 103
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 17[c]) ................................ 103
`“curing the curable liquid material in the path of
`composite material;” (Claim Element 17[d]) .............. 104
`“moving the nozzle during discharging to create
`the three-dimensional object; and” (Claim Element
`17[e]) ............................................................................ 104
`
`e.
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`f.
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`g.
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`b.
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`c.
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`d.
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`e.
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`f.
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`5.
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`TABLE OF CONTENTS
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`Page vi
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`g.
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`6.
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`“selectively cutting the continuous strand material
`before the continuous strand material reaches the
`nozzle such that at least one portion of the path
`discharging from the nozzle contains only the
`curable liquid material.” (Claim Element 17[f]) ......... 104
`Independent Claim 19 ............................................................ 107
`a.
`“A method of manufacturing a three-dimensional
`object comprising:” (Claim Element 19[pre]) ............ 108
`“discharging from a nozzle a first path of
`composite material;” (Claim Element 19[a]) .............. 108
`“curing a first portion of the first path of composite
`material, leaving a second portion of the first path
`of composite material at least partially uncured;”
`(Claim Element 19[b]) ................................................. 108
`“discharging a second path of composite material
`adjacent the first path of composite material,”
`(Claim Element 19[c]) ................................................. 111
`“wherein the composite material of each of the
`first and second paths contain a continuous strand
`material at least partially coated with a curable
`liquid material;” (Claim Element 19[d]) ..................... 113
`“curing the second path of composite material;”
`(Claim Element 19[e]) ................................................. 114
`“mechanically interlocking the second portion of
`the first path of composite material with the cured
`second path of composite material; and” (Claim
`Element 19[f]) .............................................................. 114
`“curing the second portion of the first path of
`composite material while the second portion of the
`first path of composite material is mechanically
`interlocked with the cured second path of
`composite material.” (Claim Element 19[g]) .............. 115
`7. Motivation to Combine Ma and Lipsker ................................ 115
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`b.
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`c.
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`d.
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`e.
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`f.
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`g.
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`h.
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`TABLE OF CONTENTS
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`Page vii
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`D. Ground 3: The Combination of Ma, Lipsker, and Masters
`Renders Obvious Claim 4 ................................................................ 117
`1.
`Claim 4: “wherein aiming the at least one UV light
`includes aiming a plurality of lights from different angles
`around the nozzle.” ................................................................ 117
`2. Motivation to combine Ma, Lipsker, and Masters ................. 120
`E. Ground 4 The Combination of Ma, Lipsker, and Crump
`Renders Obvious Claim 20 .............................................................. 122
`1.
`Claim 20: “wherein discharging from the nozzle the first
`path of composite material and the second path of
`composite material includes simultaneously discharging
`the first and second paths of composite material.” ................ 122
`2. Motivation to Combine Ma, Lipsker, and Crump. ................ 124
`Ground 5: The Combination of Ma and Crump Renders
`Obvious Claim 13 ............................................................................. 126
`1.
`Independent Claim 13 ............................................................ 126
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`13[pre]) ........................................................................ 126
`“directing a curable liquid material to a nozzle;”
`(Claim Element 13[a]) ................................................. 127
`“directing a continuous strand material to the
`nozzle;” (Claim Element 13[b]) .................................. 127
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 13[c]) ................................ 127
`“bonding an end point of the path of composite
`material to an anchor; and” (Claim Element 13[d]) .... 128
`“moving the nozzle during discharging to cause
`the path of composite material to extend away
`from the anchor; and” (Claim Element 13[e]) ............. 130
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`e.
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`f.
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`-vii-
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`F.
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`b.
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`c.
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`d.
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`TABLE OF CONTENTS
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`Page viii
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`g.
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`b.
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`c.
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`d.
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`“exposing the curable liquid material in the path of
`composite material to a cure energy while the
`nozzle is moving such that the path of composite
`material is hardened at a fixed location in three-
`dimensional space without support at locations
`between the anchor and the nozzle.” (Claim
`Element 13[f]) .............................................................. 131
`2. Motivation to combine Ma and Crump .................................. 134
`G. Ground 6: The Combination of Ma and Nikzad Renders
`Obvious Claim 15 ............................................................................. 134
`1.
`Independent Claim 15 ............................................................ 134
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`15[pre]) ........................................................................ 134
`“directing a curable liquid material to a nozzle;”
`(Claim Element 15[a]) ................................................. 136
`“directing a continuous strand material to the
`nozzle;” (Claim Element 15[b]) .................................. 136
`“directing flakes of fiber to the nozzle;” (Claim
`Element 15[c]) ............................................................. 136
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`and the flakes of fiber at least partially coated with
`the curable liquid material;” (Claim Element
`15[d]) ........................................................................... 139
`“moving the nozzle during discharging to create
`the three-dimensional object; and” (Claim Element
`15[e]) ............................................................................ 140
`“curing the curable liquid material in the path of
`composite material.” (Claim Element 15[f]) ............... 141
`2. Motivation to Combine Ma and Nikzad ................................ 141
`H. Ground 7: Lipsker Renders Obvious Claims 16-19 ......................... 143
`1.
`Independent Claim 16 ............................................................ 143
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`TABLE OF CONTENTS
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`Page ix
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`2.
`3.
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`b.
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`c.
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`d.
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`Independent Claim 17 ............................................................ 144
`Independent Claim 18 ............................................................ 144
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`18[pre]) ........................................................................ 144
`“directing a curable liquid material to a nozzle;”
`(Claim Element 18[a]) ................................................. 144
`“directing a continuous strand material to the
`nozzle;” (Claim Element 18[b]) .................................. 144
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 18[c]) ............................... 144
`“adjusting a trajectory of the path of uncured
`composite material to a new location after
`discharge from the nozzle; and” (Claim Element
`18[d]) ........................................................................... 145
`“curing the curable liquid material in the path of
`uncured composite material at the new location
`after adjusting.” (Claim Element 18[e]) ...................... 147
`Independent Claim 19 ............................................................ 147
`4.
`Ground 8: The Combination of Lipsker and Crump Renders
`Obvious Claim 13 and 20 ................................................................. 148
`1.
`Independent Claim 13 ............................................................ 148
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`13[pre]) ........................................................................ 148
`“directing a curable liquid material to a nozzle;”
`(Claim Element 13[a]) ................................................. 148
`“directing a continuous strand material to the
`nozzle;” (Claim Element 13[b]) .................................. 148
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`e.
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`f.
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`b.
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`c.
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`TABLE OF CONTENTS
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`Page x
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`d.
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`e.
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`f.
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`g.
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`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 13[c]) ................................ 149
`“bonding an end point of the path of composite
`material to an anchor; and” (Claim Element 13[d]) .... 149
`“moving the nozzle during discharging to cause
`the path of composite material to extend away
`from the anchor; and” (Claim Element 13[e]) ............. 152
`“exposing the curable liquid material in the path of
`composite material to a cure energy while the
`nozzle is moving such that the path of composite
`material is hardened at a fixed location in three-
`dimensional space without support at locations
`between the anchor and the nozzle.” (Claim
`Element 13[f]) .............................................................. 152
`Claim 20: “wherein discharging from the nozzle the first
`path of composite material and the second path of
`composite material includes simultaneously discharging
`the first and second paths of composite material.” ................ 154
`3. Motivation to Combine Lipsker and Crump .......................... 154
`Ground 9: The Combination of Lipsker and Nikzad Renders
`Obvious Claim 15 ............................................................................. 155
`1.
`Independent Claim 15 ............................................................ 155
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`15[pre]) ........................................................................ 155
`“directing a curable liquid material to a nozzle;”
`(Claim Element 15[a]) ................................................. 155
`“directing a continuous strand material to the
`nozzle;” (Claim Element 15[b]) .................................. 155
`“directing flakes of fiber to the nozzle;” (Claim
`Element 15[c]) ............................................................. 156
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`2.
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`b.
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`c.
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`d.
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`TABLE OF CONTENTS
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`Page xi
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`e.
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`f.
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`g.
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`b.
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`c.
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`d.
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`e.
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`f.
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`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`and the flakes of fiber at least partially coated with
`the curable liquid material;” (Claim Element
`15[d]) ........................................................................... 157
`“moving the nozzle during discharging to create
`the three-dimensional object; and” (Claim Element
`15[e]) ............................................................................ 157
`“curing the curable liquid material in the path of
`composite material.” (Claim Element 15[f]) ............... 158
`2. Motivation to Combine Lipsker and Nikzad ......................... 158
`K. Ground 10: The Combination of Lipsker and Ma Renders
`Obvious Claims 1-3, 5-12, and 14 ................................................... 160
`1.
`Independent Claim 1 .............................................................. 160
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`1[pre]) .......................................................................... 160
`“directing a curable liquid material to a nozzle;”
`(Claim Element 1[a]) ................................................... 160
`“directing a continuous strand material to the
`nozzle;” (Claim Element 1[b]) .................................... 160
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 1[c]) .................................. 161
`“bonding an end point of the path of composite
`material to an anchor; and” (Claim Element 1[d]) ...... 161
`“moving the nozzle away from the anchor during
`discharging to pull the path of composite material
`out of the nozzle.” (Claim Element 1[e]) .................... 161
`Claim 2: “wherein bonding the end point of the path of
`composite material to the anchor includes:” .......................... 163
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`2.
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`TABLE OF CONTENTS
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`Page xii
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`3.
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`4.
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`5.
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`6.
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`7.
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`8.
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`9.
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`“placing the end point of the path of composite
`material on the anchor; and” (Claim Element 2[a]) .... 163
`“aiming a curing device at the path of composite
`material on the anchor.” (Claim Element 2[b]) ........... 163
`Claim 3: “wherein aiming the curing device includes
`aiming at least one UV light.”................................................ 164
`Claim 5: “wherein aiming the at least one UV light
`includes aiming the at least one UV light from only a
`trailing side of the nozzle.” .................................................... 164
`Claim 6: “wherein discharging from the nozzle the path
`of composite material includes discharging the path of
`composite material through a nozzle orifice having a
`diameter of about 2 mm.” ...................................................... 164
`Claim 7: “wherein the continuous strand material
`includes a plurality of strands arranged in at least one of a
`tow, a roving, and a weave.” .................................................. 165
`Claim 8: “wherein directing the curable liquid material to
`the nozzle includes directing a filler material at least
`partially coated in the curable liquid material to the
`nozzle.” .................................................................................. 166
`Claim 9: “wherein the filler material includes pieces of
`fibers.” .................................................................................... 167
`Claim 10: “wherein the continuous strand material is
`hollow.” .................................................................................. 167
`10. Claim 11 ................................................................................. 168
`a.
`“further including: curing a first portion of the path
`of composite material;” (Claim Element 11[a]) .......... 168
`“overlapping the first portion of the path of
`composite material with a second portion of the
`path of composite material that is uncured; and”
`(Claim Element 11[b]) ................................................. 169
`
`a.
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`b.
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`b.
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`Page xiii
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`c.
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`12.
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`“curing the second portion of the path of
`composite material while the first and second
`portions of the path of composite material are
`overlapped.” (Claim Element 11[c] ............................. 170
`11. Claim 12: “wherein the overlapping includes wrapping
`the second portion of the path of composite material
`around the first portion of the path of composite
`material.” ................................................................................ 171
`Independent Claim 14 ............................................................ 171
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`14[pre]) ........................................................................ 171
`“directing a curable liquid material to a nozzle;”
`(Claim Element 14[a]) ................................................. 171
`“directing a continuous strand material to the
`nozzle;” (Claim Element 14[b]) .................................. 172
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 14[c]) ................................ 172
`“curing the curable liquid material in the path of
`composite material; and” (Claim Element 14[d]) ....... 172
`“moving the nozzle during discharging to create
`tension in the continuous strand material that
`remains after curing of the composite material.”
`(Claim Element 14[e]) ................................................. 172
`13. Motivation to Combine Lipsker and Ma ................................ 173
`L. Ground 11: The Combination of Lipsker, Ma, and Masters
`Renders Obvious Claim 4 ................................................................ 173
`1.
`Claim 4: “wherein aiming the at least one UV light
`includes aiming a plurality of lights from different angles
`around the nozzle.” ................................................................ 173
`2. Motivation to combine Lipsker, Ma, and Masters ................. 173
`-xiii-
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`f.
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`(continued)
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`Page xiv
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`M. Ground 12: Wohrl Renders Obvious Claims 1, 2, 11, 16, and 18 ... 174
`1.
`Independent Claim 1 .............................................................. 174
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`1[pre]) .......................................................................... 174
`“directing a curable liquid material to a nozzle;”
`(Claim Element 1[a]) ................................................... 174
`“directing a continuous strand material to the
`nozzle;” (Claim Element 1[b]) .................................... 176
`“discharging from the nozzle a path of composite
`material containing the continuous strand material
`at least partially coated with the curable liquid
`material;” (Claim Element 1[c]) .................................. 176
`“bonding an end point of the path of composite
`material to an anchor; and” (Claim Element 1[d]) ...... 177
`“moving the nozzle away from the anchor during
`discharging to pull the path of composite material
`out of the nozzle.” (Claim Element 1[e]) ................... 178
`Claim 2: “wherein bonding the end point of the path of
`composite material to the anchor includes:” .......................... 179
`a.
`“placing the end point of the path of composite
`material on the anchor; and” (Claim Element 2[a]) .... 179
`“aiming a curing device at the path of composite
`material on the anchor.” (Claim Element 2[b]) ........... 179
`Claim 11 ................................................................................. 181
`a.
`“further including: curing a first portion of the path
`of composite material;” (Claim Element 11[a]) .......... 181
`“overlapping the first portion of the path of
`composite material with a second portion of the
`path of composite material that is uncured; and”
`(Claim Element 11[b]) ................................................. 183
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`d.
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`2.
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`3.
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`TABLE OF CONTENTS
`(continued)
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`Page xv
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`c.
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`b.
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`c.
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`d.
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`“curing the second portion of the path of
`composite material while the first and second
`portions of the path of composite material are
`overlapped.” (Claim Element 11[c] ............................ 184
`Claim 12: “wherein the overlapping includes wrapping
`the second portion of the path of composite material
`around the first portion of the path of composite
`material.” ................................................................................ 184
`Independent Claim 16 ............................................................ 186
`a.
`“A method of manufacturing of a three-
`dimensional object, comprising:” (Claim Element
`16[pre]) ........................................................................ 187
`“directing a curable liquid ma



