May 19, 2026

US12631415 - 3D-printed support structures for sound suppressors

Sound suppressors are provided. The sound suppressor includes an engagement, attachable to a barrel of a firearm, and one or more baffle structures manufactured by 3D printing and forming a baffle stack. Each baffle structure includes one or more baffles housed within a wall. The baffles are connected to one another and to the wall by one or more supports, which provide for improved structural strength. The supports further define channels between the baffles and the wall, decreasing weight without sacrificing structural strength. The channels are open or sealed to facilitate flow of pressurized gas between chambers defined by the baffles and the wall, the pressurized gas being generated during discharge of the firearm. The pressurized gas decompresses and cools while traveling between the chambers and the channels, thereafter exiting the sound suppressor at a decreased pressure, temperature, and velocity, which may attenuate a noise associated with the discharge.

Assignee: Q,LLC
Inventors: Ethan Michel Lessard
Filing date: 2024-05-10

firearmsuppressor3dprinting

The patent describes a sound suppressor that utilizes 3D-printed baffle structures to enhance structural strength while reducing weight, featuring channels that facilitate the flow of pressurized gas. This design aims to decrease the noise associated with firearm discharge by allowing gas to decompress and cool as it travels through the suppressor.

Claim 1

1 . A sound suppressor, comprising: an engagement, configured to mate with a barrel of a firearm; and a first baffle structure, mated to the engagement, including: a first baffle, having a first cone, defining a first profile extending from a first diameter to a second diameter, the second diameter being smaller than the first diameter, a first structural component, wherein the first structural component is one of a second baffle or a wall of the sound suppressor, and a first support extending from the first baffle to the first structural component, wherein the first support defines a first channel disposed within the first support. an engagement, configured to mate with a barrel of a firearm; and a first baffle structure, mated to the engagement, including: a first baffle, having a first cone, defining a first profile extending from a first diameter to a second diameter, the second diameter being smaller than the first diameter, a first structural component, wherein the first structural component is one of a second baffle or a wall of the sound suppressor, and a first support extending from the first baffle to the first structural component, wherein the first support defines a first channel disposed within the first support. a first baffle, having a first cone, defining a first profile extending from a first diameter to a second diameter, the second diameter being smaller than the first diameter, a first structural component, wherein the first structural component is one of a second baffle or a wall of the sound suppressor, and a first support extending from the first baffle to the first structural component, wherein the first support defines a first channel disposed within the first support.

Google Patents

https://patents.google.com/patent/US12631415

USPTO PDF

https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/12631415