公开(公告)号：US20210178675A1

公开(公告)日：2021-06-17

申请号：US16761623

申请日：2018-11-02

Applicant: General Electric Company

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding

IPC: B29C64/209 ,  B29C64/268 ,  B29C64/364 ,  B29C64/165 ,  B29C64/214 ,  B33Y30/00 ,  F16F15/08

Abstract: An additive manufacturing machine (900) includes a build unit (904) that is supported by an overhead gantry (918). The build unit (904) includes a powder dispenser (906) including a vibration mechanism (922) and a scan unit (908) including a powder fusing device (910) for fusing or binding portions of a layer of additive powder. A vibration isolation device (932), such as a passive rubber damper (940) or an active vibration canceling mechanism (960), is positioned between the powder dispenser (906) and the scan unit (908) to prevent vibrations in the powder dispenser (906) from causing operational issues with the scan unit (908) and inaccuracies in the additive manufacturing process.

公开(公告)号：US10981232B2

公开(公告)日：2021-04-20

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 ,  B22F12/00 ,  B22F10/10

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：US20210031266A1

公开(公告)日：2021-02-04

申请号：US17072163

申请日：2020-10-16

Applicant: General Electric Company

Inventor： MacKenzie Ryan Redding ,  Zachary David Fieldman ,  Justin Mamrak

IPC: B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K26/342 ,  B23K26/14 ,  B23K15/00 ,  B29C64/153 ,  B33Y40/00 ,  B29C64/371 ,  B23K26/08

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：US20200324340A1

公开(公告)日：2020-10-15

申请号：US16761616

申请日：2018-11-02

Applicant: General Electric Company

Inventor： MacKenzie Ryan Redding ,  Frank Schodel

IPC: B22F3/105 ,  B33Y10/00

Abstract: An additive manufacturing machine (910) includes a build platform (908) extending within a horizontal plane (H) and a gantry (930) positioned above the build platform (908) and defining a build area (932). A build unit (920) includes a powder dispenser (906) for discharging a layer of additive powder (902) and an energy source (922) for selectively directing energy toward the layer of additive powder (902) to fuse portions of the layer of additive powder (902). The gantry (930) movably supports the build unit (920) within the build area and a powder supply system (900) is positioned below the gantry (930) and extends between a powder supply source (940) and the powder dispenser (906).

公开(公告)号：US10799953B2

公开(公告)日：2020-10-13

申请号：US15945082

申请日：2018-04-04

Applicant: General Electric Company

Inventor： MacKenzie Ryan Redding ,  Justin Mamrak ,  Zachary David Fieldman

IPC: B22F3/105 ,  B29C64/364 ,  B29C64/268 ,  B23K15/00 ,  B23K37/00 ,  B23K26/08 ,  B23K26/14 ,  B23K26/342 ,  B33Y50/02 ,  B33Y30/00 ,  B33Y10/00 ,  B29C64/153 ,  B23K26/082 ,  B29C64/40 ,  B23K26/142 ,  B29C64/205

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：US20200254566A1

公开(公告)日：2020-08-13

申请号：US16761691

申请日：2018-11-02

Applicant: General Electric Company

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B23K26/082 ,  B23K26/08 ,  B23K26/14

Abstract: An additive manufacturing apparatus is provided and may include at least one build unit; a build platform; and at least one collector positioned on the apparatus such that the at least one collector contacts an outer surface of a build wall as the build wall is formed during a build. Methods are also provided for manufacturing at least one object.

公开(公告)号：US10022794B1

公开(公告)日：2018-07-17

申请号：US15406467

申请日：2017-01-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： MacKenzie Ryan Redding ,  Zachary David Fieldman ,  Justin Mamrak

IPC: B22F3/10 ,  B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K15/00 ,  B23K26/342 ,  B23K26/08 ,  B23K37/02 ,  B23K26/14

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：US11612937B2

公开(公告)日：2023-03-28

申请号：US16761616

申请日：2018-11-02

Applicant: General Electric Company

Inventor： MacKenzie Ryan Redding ,  Frank Schodel

IPC: B22F10/20 ,  B29C64/153 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: An additive manufacturing machine (910) includes a build platform (908) extending within a horizontal plane (H) and a gantry (930) positioned above the build platform (908) and defining a build area (932). A build unit (920) includes a powder dispenser (906) for discharging a layer of additive powder (902) and an energy source (922) for selectively directing energy toward the layer of additive powder (902) to fuse portions of the layer of additive powder (902). The gantry (930) movably supports the build unit (920) within the build area and a powder supply system (900) is positioned below the gantry (930) and extends between a powder supply source (940) and the powder dispenser (906).

公开(公告)号：US11364564B2

公开(公告)日：2022-06-21

申请号：US15811283

申请日：2017-11-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding ,  Mark Kevin Meyer

IPC: B23K15/00 ,  B33Y10/00 ,  B33Y30/00 ,  B23K26/342 ,  B23K15/08 ,  B23K26/082 ,  B23K26/14 ,  B33Y70/00

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：US11253922B2

公开(公告)日：2022-02-22

申请号：US15610214

申请日：2017-05-31

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Brandon Holford ,  Jeffrey Vaught ,  MacKenzie Ryan Redding ,  Justin Mamrak

IPC: B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y80/00 ,  B33Y40/00 ,  B22F5/00 ,  B22F5/04 ,  B23K15/00 ,  B33Y50/02 ,  B23K26/342 ,  B23K26/70 ,  B23K26/08 ,  F01D25/24 ,  F23R3/00 ,  B22F10/20 ,  B23K26/14 ,  B23K26/144 ,  B22F5/10 ,  B23K101/00 ,  F01D5/22 ,  B22F10/30

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.