公开(公告)号：US12240180B2

公开(公告)日：2025-03-04

申请号：US16804629

申请日：2020-02-28

Applicant: The Boeing Company

Inventor： Alexander J. Coco ,  Brianna K. Nord ,  Robert W. Grube ,  Emma Romig ,  Aaron C. Drollette ,  Eric M. Chapman

IPC: B29C67/00 ,  B29C64/393 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B29C64/153

Abstract: An example method for detection of impurities in additive manufacturing material includes illuminating, by a light source, a sample of additive manufacturing material with light, while illuminating the sample of the additive manufacturing material with light, causing a camera to acquire image data of the sample, and processing the image data to determine an amount of impurities in the sample of the additive manufacturing material. An example system for detection of impurities in additive manufacturing material includes a light source for illuminating a sample of additive manufacturing material with light, a camera for acquiring image data of the sample while illuminating the sample of the additive manufacturing material with light, and a computing device having one or more processors configured to execute instructions stored in memory for processing the image data to determine an amount of impurities in the sample of the additive manufacturing material.

公开(公告)号：US20240190081A1

公开(公告)日：2024-06-13

申请号：US18323686

申请日：2023-05-25

Applicant: The Boeing Company

Inventor： Dana A. Henshaw ,  Eric M. Chapman

IPC: B29C64/393 ,  B29C64/153 ,  B29C64/321

CPC classification number: B29C64/393 ,  B29C64/153 ,  B29C64/321 ,  B33Y10/00

Abstract: Methods of manufacturing a manufactured component, additive manufacturing systems that perform the methods, and storage media that directs additive manufacturing systems to perform the methods. The methods include determining a process parameter value and determining a spatial offset parameter value based upon the process parameter value. The methods also include forming the manufactured component utilizing the additive manufacturing system. The forming includes supplying a feedstock material, delivering, to an addition location, an amount of energy sufficient to form a melt pool of the feedstock material, and moving the addition location along a scan path to define a plurality of consolidated material tracks from the feedstock material. Each consolidated material track extends between a corresponding initiation location and a corresponding termination location, and a location of at least one of the corresponding initiation location and the corresponding termination location is based on the spatial offset parameter value.

公开(公告)号：US11845201B2

公开(公告)日：2023-12-19

申请号：US17492031

申请日：2021-10-01

Applicant: The Boeing Company

Inventor： Eric M. Chapman ,  Cory C. Cunningham ,  Troy A. Haworth ,  Dana Alexander Henshaw ,  Matthew Thomas Hollinger ,  Ashley Marie Jones ,  Kevin Michael Mejia ,  Christopher Perez ,  Russell William Waymire

IPC: B29C64/386 ,  B29C64/153 ,  B33Y50/00 ,  B33Y10/00 ,  B29C64/371 ,  B33Y30/00

CPC classification number: B29C64/386 ,  B29C64/153 ,  B29C64/371 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/00

Abstract: A method of configuring an additive-manufacturing machine comprises a chamber, a platform, movable inside the chamber and comprising a build-plane surface, and a laser, having a laser focal plane within the chamber. The method comprising steps of flowing a gas within the chamber in accordance with a first set of process parameters and identifying a value of a flow characteristic of the gas at a predetermined point in the laser focal plane while flowing the gas within the chamber in accordance with the first set of process parameters. The method also comprises additively manufacturing a test coupon using the laser while flowing the gas within the chamber in accordance with the first set of process parameters, wherein the test coupon has a test-coupon peripheral surface.

公开(公告)号：US20240190083A1

公开(公告)日：2024-06-13

申请号：US18323791

申请日：2023-05-25

Applicant: The Boeing Company

Inventor： Dana A. Henshaw ,  Eric M. Chapman

IPC: B29C64/393 ,  B29C64/153 ,  B29C64/321

CPC classification number: B29C64/393 ,  B29C64/153 ,  B29C64/321 ,  B33Y10/00

Abstract: Methods of manufacturing a manufactured component, additive manufacturing systems that perform the methods, and storage media that directs additive manufacturing systems to perform the methods. The methods include supplying a feedstock material along a scan path. The methods also include delivering, to an addition location, an amount of energy sufficient to form a melt pool of the feedstock material at the addition location. The methods further include, during the delivering the amount of energy, moving the addition location along the scan path to move the melt pool along the scan path and define a consolidated material track from the feedstock material. The methods also include determining that the melt pool is within a threshold proximity of a merge region and adjusting a process parameter value of the additive manufacturing system from a process parameter pre-merge-region value to a process parameter post-merge-region value that differs from the process parameter pre-merge-region value.

公开(公告)号：US20240066597A1

公开(公告)日：2024-02-29

申请号：US17895870

申请日：2022-08-25

Applicant: The Boeing Company

Inventor： Dana Alexander Henshaw ,  Eric M. Chapman

IPC: B22F10/36 ,  B22F12/30 ,  B22F12/40 ,  B22F12/50 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

CPC classification number: B22F10/36 ,  B22F12/30 ,  B22F12/40 ,  B22F12/50 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

Abstract: Methods of additively manufacturing a manufactured component and systems that perform the methods. The methods include determining an energy application parameter at an addition location on a previously formed portion of the manufactured component. The methods also include supplying a feedstock material to the addition location. The methods further include delivering, from an energy source and to the addition location, an amount of energy sufficient to form a melt pool of the feedstock material at the addition location. The amount of energy is based, at least in part, on the energy application parameter. The methods also include consolidating the melt pool with a previously formed portion to form an additional portion of the manufactured component. The delivering includes delivering the amount of energy to the addition location along an axis of incidence, and the energy application parameter includes a directionality parameter that is based on the axis of incidence.

公开(公告)号：US20240059017A1

公开(公告)日：2024-02-22

申请号：US18497934

申请日：2023-10-30

Applicant: The Boeing Company

Inventor： Eric M. Chapman ,  Cory C. Cunningham ,  Troy A. Haworth ,  Dana Alexander Henshaw ,  Matthew Thomas Hollinger ,  Ashley Marie Jones ,  Kevin Michael Mejia ,  Christopher Perez ,  Russell William Waymire

IPC: B29C64/386 ,  B29C64/153 ,  B33Y50/00 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/371

CPC classification number: B29C64/386 ,  B29C64/153 ,  B33Y50/00 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/371

Abstract: A method includes flowing gas within a chamber for first process parameters at a predetermined point in a laser focal plane and simulating the step of flowing gas within the chamber based on the value of the flow characteristic of the gas at the predetermined point in the laser focal plane so that a value of a simulated-flow characteristic of the gas at a predetermined point away from the laser focal plane is identified. The method comprises comparing the value of the simulated-flow characteristic of gas at the predetermined point away from the laser focal plane to a desired value of the simulated-flow characteristic and flowing gas within the chamber for second differing process parameters, when the value of the simulated-flow characteristic of the gas at the predetermined point away from the laser focal plane differs from the desired value of the simulated-flow characteristic is outside a predetermined range.

公开(公告)号：US11772195B2

公开(公告)日：2023-10-03

申请号：US16854104

申请日：2020-04-21

Applicant: THE BOEING COMPANY

Inventor： Eric M. Chapman ,  Dana A. Henshaw

IPC: B23K26/342 ,  B33Y30/00 ,  B33Y50/02 ,  B23K26/06 ,  B23K26/08 ,  G05B19/402 ,  G05B19/4099

CPC classification number: B23K26/342 ,  B23K26/0604 ,  B23K26/0876 ,  B33Y30/00 ,  B33Y50/02 ,  G05B19/402 ,  G05B19/4099 ,  G05B2219/49023

Abstract: An additive manufacturing system includes one or more processors configured to determine one or more geometrical characteristics of each of multiple segments of a build part at a candidate position relative to an additive manufacturing instrument. The one or more geometrical characteristics include an angle of incidence between a beam line extending from a beam source and a surface normal of a respective skin of the corresponding segment proximate to the beam line. The one or more processors are configured to control the additive manufacturing instrument, based on the one or more geometrical characteristics, to direct focused energy beams from a first orientation relative to the build part to form a first segment of the segments of the build part and to direct focused energy beams from a second orientation relative to the build part to form a second segment of the segments of the build part.

公开(公告)号：US20210323089A1

公开(公告)日：2021-10-21

申请号：US16853959

申请日：2020-04-21

Applicant: THE BOEING COMPANY

Inventor： Eric M. Chapman ,  Dana A. Henshaw

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K26/04 ,  B23K26/082 ,  B23K26/08 ,  B23K26/10 ,  B23K26/70

Abstract: An additive manufacturing system includes one or more processors configured to determine one or more geometrical characteristics of each of multiple segments of a build part at a candidate position of the build part relative to an additive manufacturing instrument. The one or more geometrical characteristics include an angle of incidence between a beam line extending from an electromagnetic energy source of the additive manufacturing instrument and a surface normal of a respective skin of the corresponding segment proximate to the beam line. The one or more processors are configured to determine, based on one or more geometrical characteristics of the segments at the candidate position, one or more locations of support material to be formed adjacent the build part during a build process of the build part.

公开(公告)号：US11073824B1

公开(公告)日：2021-07-27

申请号：US16854017

申请日：2020-04-21

Applicant: THE BOEING COMPANY

Inventor： Eric M. Chapman ,  Dana A. Henshaw

IPC: G05B19/418 ,  G01B21/20 ,  B29C64/386 ,  B33Y50/00

Abstract: An additive manufacturing system includes one or more processors configured to determine one or more geometrical characteristics of each of multiple segments of a build part at a candidate position of the build part relative to a platform. The one or more processors are configured to generate a quality score for each of the segments at the candidate position based on the one or more geometrical characteristics, The one or more processors are also configured to generate a simulation model of the build part at the candidate position for display. The simulation model includes graphic indicators corresponding to each of the segments. The graphic indicators are representative of the quality scores of the corresponding segments.