公开(公告)号：US20180250749A1

公开(公告)日：2018-09-06

申请号：US15968795

申请日：2018-05-02

Applicant: GENERAL ELECTRIC COMPANY

Inventor： MacKenzie Ryan REDDING ,  Zachary David FIELDMAN ,  Justin MAMRAK

IPC: B22F3/105 ,  B23K37/02 ,  B23K26/08 ,  B23K15/00 ,  B23K26/342 ,  B33Y10/00 ,  B23K26/14 ,  B33Y50/02 ,  B33Y40/00 ,  B33Y30/00

CPC classification number: B22F3/1055 ,  B22F2003/1056 ,  B23K15/002 ,  B23K15/0086 ,  B23K26/0876 ,  B23K26/1437 ,  B23K26/342 ,  B23K37/0235 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02 ,  Y02P10/295

Abstract: The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the “gas plume”) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

公开(公告)号：US20180250743A1

公开(公告)日：2018-09-06

申请号：US15451108

申请日：2017-03-06

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin MAMRAK ,  MacKenzie Ryan REDDING

IPC: B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K26/342 ,  B23K15/00 ,  B23K26/082

Abstract: A scanning technique for the additive manufacturing of an object. The method comprises the irradiation of a portion of a given layer of powder to form a fused region using an energy source. When forming an object layer by layer, the irradiation follows a first irradiation path bounded by a first stripe, wherein the first irradiation path is formed at an oblique angle with respect to the first stripe. The first irradiation path further comprises at least a first scan vector and a second scan vector at least partially melting a powder and forming a first solidification line and second solidification line respectively, wherein the first solidification intersects and forms an oblique angle with respect to the second solidification line. After a layer is completed, a subsequent layer of powder is provided over the completed layer, and the subsequent layer of powder is irradiated. Irradiation of the subsequent layer of powder follows a second irradiation path bounded by a second stripe. wherein the second irradiation path is formed at an oblique angle with respect to the second stripe. The first irradiation path further comprises at least a third scan vector and a fourth scan vector at least partially melting a powder and forming a third solidification line and fourth solidification line respectively, wherein the third solidification intersects and forms an oblique angle with respect to the fourth solidification line

公开(公告)号：US20180200962A1

公开(公告)日：2018-07-19

申请号：US15406444

申请日：2017-01-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： MacKenzie Ryan REDDING ,  Justin MAMRAK ,  Zachary David FIELDMAN

IPC: B29C67/00 ,  B22F3/105 ,  B33Y10/00

CPC classification number: B22F3/1055 ,  B22F2003/1056 ,  B22F2003/1058 ,  B29C64/153 ,  B29C64/40 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y70/00 ,  Y02P10/295

Abstract: The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the “gas plume”) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

公开(公告)号：US20190134911A1

公开(公告)日：2019-05-09

申请号：US15807443

申请日：2017-11-08

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Lucas Christian JONES ,  Justin MAMRAK

IPC: B29C64/393 ,  G06K9/00 ,  G06T7/564 ,  G03F7/20 ,  G03F7/00 ,  G06K9/20 ,  B29C64/153 ,  B29C64/223 ,  B22F3/105

Abstract: A method, apparatus, and program for build surface mapping and recovery for additive manufacturing. The method may include fabricating an object by additive manufacturing wherein the topology of a build surface is determined. An additive manufacturing process may be modified based on the topology determination. The topology of the surface may be determined by marking the surface with a first mark using a converging energy source; determining a dimension of the mark using a camera; and determining a height of the first mark based on the dimension of the mark.

公开(公告)号：US20180345379A1

公开(公告)日：2018-12-06

申请号：US15609909

申请日：2017-05-31

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Brandon HOLFORD ,  Jeffrey VAUGHT ,  MacKenzie Ryan REDDING ,  Justin MAMRAK

IPC: B22F3/24 ,  B33Y10/00 ,  B33Y30/00 ,  B22F3/105 ,  B33Y40/00

Abstract: An apparatus for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit and the machining mechanism are attached to a positioning mechanism that provides them with movement. The build platform of the apparatus is rotating and preferably vertically stationary. Embodiments of the build unit that further includes a gas-flow mechanism and the build platform having a dynamically grown wall are also described. A manufacturing method using the apparatus involves rotating the build platform; repetitive cycles of moving the build unit(s) to deposit a powder and irradiating the powder to form a fused additive layer; and machining the object being manufactured.

公开(公告)号：US20180264598A1

公开(公告)日：2018-09-20

申请号：US15459941

申请日：2017-03-15

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin MAMRAK

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B23K15/00

CPC classification number: B33Y30/00 ,  B22F3/1055 ,  B22F2003/1056 ,  B23K2103/05 ,  B23K2103/10 ,  B33Y10/00

Abstract: An improved scanning strategy, having a waveform hatch pattern for scanning an energy source during an additive manufacturing build process. A waveform hatch pattern is formed on each layer of the build so as to increase the variance between layers and/or improve the microstructure of the completed component. In one aspect, a first layer is formed by scanning a laser in a series of hatch lines formed as a first pattern that oscillates about an axis. Each subsequent layer is formed as a series hatch lines formed in a pattern that is varied in geometry from a previous and subsequently formed layer. By varying the pattern when forming each layer, the desired variance in each layer can be achieved.

公开(公告)号：US20180200792A1

公开(公告)日：2018-07-19

申请号：US15406467

申请日：2017-01-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： MacKenzie Ryan REDDING ,  Zachary David FIELDMAN ,  Justin MAMRAK

IPC: B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K15/00 ,  B23K26/342 ,  B23K26/08 ,  B23K37/02 ,  B23K26/14

CPC classification number: B22F3/1055 ,  B22F2003/1056 ,  B22F2003/1059 ,  B23K15/002 ,  B23K15/0086 ,  B23K15/0093 ,  B23K26/0006 ,  B23K26/082 ,  B23K26/0876 ,  B23K26/127 ,  B23K26/14 ,  B23K26/1437 ,  B23K26/342 ,  B23K37/0235 ,  B23K2103/00 ,  B23K2103/26 ,  B23K2103/42 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the “gas plume”) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

公开(公告)号：US20180200791A1

公开(公告)日：2018-07-19

申请号：US15406336

申请日：2017-01-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： MacKenzie Ryan REDDING ,  Justin MAMRAK ,  Zachary David FIELDMAN

IPC: B22F3/105 ,  B29C67/00 ,  B29C35/08 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K15/00 ,  B23K15/02 ,  B23K26/342 ,  B23K26/70

CPC classification number: B22F3/1055 ,  B22F2003/1056 ,  B22F2003/1057 ,  B22F2999/00 ,  B29C64/153 ,  B29C64/214 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B22F2203/03 ,  B22F2203/13

Abstract: The present disclosure generally relates to additive manufacturing systems and methods involving a recoater blade to smooth out deposited powder, such that the system can sense forces on the blade and allow vertical and horizontal displacement of the blade in response to those forces. The system can change how the blade responds to those forces, for instance the blade may respond by displacing quickly and easily away from the force (a “soft” recoater), or it may resist the force (a “stiff” recoater). This allows a single recoater blade to be used in a variety of situations without work stoppage, whereas before the blade would have to be replaced.

公开(公告)号：US20190143587A1

公开(公告)日：2019-05-16

申请号：US15811196

申请日：2017-11-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin MAMRAK ,  MacKenzie Ryan REDDING ,  Mark Kevin MEYER

IPC: B29C64/223 ,  B29C64/268 ,  B29C64/147

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

公开(公告)号：US20190143452A1

公开(公告)日：2019-05-16

申请号：US15811400

申请日：2017-11-13

Applicant: General Electric Company

Inventor： Justin MAMRAK ,  Mackenzie REDDING

IPC: B23K26/342 ,  B32B37/06 ,  B32B41/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B23K15/00 ,  B23K26/082 ,  B23K26/16 ,  B23K26/08 ,  B23K35/02

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.