公开(公告)号：US20210229361A1

公开(公告)日：2021-07-29

申请号：US16774982

申请日：2020-01-28

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Broc William TenHouten ,  Eahab Nagi El Naga

IPC: B29C64/35 ,  B29C64/153 ,  B29C64/214 ,  B29C64/264 ,  B29C64/364 ,  B29C64/255

Abstract: Techniques for cleaning a print chamber using a gas exchange structure and a re-coater are introduced. The gas exchange structure is coupled to the coater, and the two move in a same direction to benefit from the gas flow. In an embodiment, the gas exchange structure includes a manifold. Further, in an embodiment, a travelling wall may be coupled to a longitudinal axis of the re-coater in order to keep separate the clean chamber from the dirty chamber. The result is that gas contaminants caused largely by the fusion and melting processes are removed from the powder bed and chamber at each cycle, and the resulting 3-D produced component maintains a very high quality for a long period of time.

公开(公告)号：US11020800B2

公开(公告)日：2021-06-01

申请号：US15968708

申请日：2018-05-01

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Eahab Nagi El Naga ,  Ross Harrison Byers ,  Keith Allen Fleming ,  Steven Blair Massey, Jr. ,  Narender Shankar Lakshman ,  Antonio Bernerd Martinez

IPC: B22F3/24 ,  B33Y10/00 ,  B33Y80/00 ,  B33Y40/00 ,  B22F10/00

Abstract: Apparatus and methods for sealing powder holes in additively manufactured parts are presented herein. Powder holes are co-printed to facilitate post processing sealing. Embodiments include co-printed caps, friction welded caps, rivets, silicone plugs, co-printed tangs, multiple micro holes, layup, and spin forming. By using one or more of the above techniques, powder holes can be sealed on additively manufactured parts.

公开(公告)号：US20210148449A1

公开(公告)日：2021-05-20

申请号：US17118402

申请日：2020-12-10

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Antonio Bernerd Martinez ,  Eahab Nagi El Naga ,  David Brian TenHouten ,  John Russell Bucknell ,  Broc William TenHouten ,  Chukwubuikem Mercel Okoli ,  Thomas Samuel Bowden, JR. ,  Muhammad Faizan Zafar

IPC: F16H57/029 ,  B33Y10/00 ,  B33Y80/00 ,  B32B1/08 ,  B32B15/04 ,  B32B37/12 ,  B32B7/12 ,  B32B37/24 ,  B32B3/06 ,  B23K26/342 ,  F16H57/032 ,  B22F7/08

Abstract: Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.

公开(公告)号：US10898968B2

公开(公告)日：2021-01-26

申请号：US15582493

申请日：2017-04-28

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Eahab Nagi El Naga ,  John Russell Bucknell

IPC: B23K15/00 ,  B22F3/105 ,  B33Y10/00 ,  B33Y30/00

Abstract: Systems and methods for reducing charged powder particle scattering in powder-bed fusion (PBF) systems are provided. A PBF apparatus can include a structure that supports a layer of powder material having a plurality of particles of powder. For example, the structure can be a build plate, a build floor, a build piece, etc. The apparatus can also include an energy beam source that generates an energy beam and a deflector that applies the energy beam to fuse an area of the powder material in the layer. The energy beam can electrically charge the particles of powder. The apparatus can also include an electrical system that generates an electrical force between the structure and the charged particles of powder. For example, the electrical system can include a voltage source that applies a first voltage to the structure.

公开(公告)号：US20200147690A1

公开(公告)日：2020-05-14

申请号：US16678625

申请日：2019-11-08

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Broc William TenHouten ,  Eahab Nagi El Naga

IPC: B22F3/105 ,  B33Y30/00

Abstract: Aspects are provided relating to additive manufacturing. In one aspect, an apparatus for producing a three-dimensional (3D) structure is described that includes a build chamber having a top portion with windows through which radiative energy from one or more sources is provided to the build chamber to produce the 3D structure, and one or more manifolds disposed within the build chamber. The manifolds are configured to perform a gas exchange within the build chamber, and each manifold is positioned above a region where envelopes of radiative energy from the one or more sources overlap. In another aspect, the manifolds are moved to a first position adjacent to the top portion of the build chamber during a first mode of operation and moved to a second position away from the top portion of the build chamber during a second mode of operation.

公开(公告)号：US20200033833A1

公开(公告)日：2020-01-30

申请号：US16046462

申请日：2018-07-26

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Alexander Pai-chung Teng ,  Eahab Nagi El Naga ,  Steven Blair Massey, JR.

IPC: G05B19/4099 ,  C23C24/04 ,  B33Y10/00 ,  B33Y50/02

Abstract: Systems, apparatus, and method for manufacturing a structure are disclosed. The structure includes a first portion, a second portion, and a structural joint. The apparatus is configured to receive instructions for printing the structural joint. The instructions are based on a data model of the structural joint. The apparatus is also configured to receive the first portion and the second portion, the first portion having a first conical tip and the second portion having a second conical tip. The apparatus is further configured to receive material. Additionally, the apparatus is configured to print the structural joint based on the instructions. The printing may include spray forming the material to produce the structural joint. The structural joint connects the first portion to the second portion.

公开(公告)号：US20190146456A1

公开(公告)日：2019-05-16

申请号：US15809913

申请日：2017-11-10

Applicant: Divergent Technologies, Inc.

Inventor： Kevin Robert Czinger ,  Broc William TenHOUTEN ,  Antonio Bernerd Martinez ,  Steven Blair Massey ,  Narender Shankar Lakshman ,  Bill David Kreig ,  Jon Paul Gunner ,  David Brian TenHOUTEN ,  Eahab Nagi El Naga ,  Muhammad Faizan Zafar

IPC: G05B19/4099 ,  G06F17/50 ,  B28B1/00 ,  B22F3/105

Abstract: A high precision Interface Node is disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. The Interface Node may connect with another component or a Linking Node. The Interface Node is manufactured to achieve high precision functionality while enabling volume production. Current additive manufacturing technologies allow for the printing of high precision features to be manufactured, but generally this is performed at a slower rate. Consequently, in one aspect, the size of the Interface Nodes is reduced in order to overcome at least part of the slower production volume caused by creating the high precision Interface Nodes. The components and Linking Nodes to which the Interface Node is connected may only have basic features and functions. Accordingly, this latter category of components may use a high print rate and thus high production volume. In other embodiments, these low precision components may also be produced using a non-print manufacturing technology, such as casting, forging, etc., that may provide the requisite high throughput, or to high precision machined parts that lack the geometric flexibility of the Interface Node. In an embodiment, the Interface Nodes may be connected to other components via a Linking Node.

公开(公告)号：US10173255B2

公开(公告)日：2019-01-08

申请号：US15619326

申请日：2017-06-09

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Broc William TenHouten ,  Eahab Nagi El Naga ,  Richard Winston Hoyle ,  Kevin Robert Czinger

IPC: B62D25/04 ,  B21D47/01 ,  B21D53/88 ,  B21D7/12 ,  B21D9/05 ,  B21C23/14

Abstract: A metal extrusion and nodes based structure is provided. The structure comprises one or more arc members connected by one or more node members, wherein the arc comprises (i) a wing feature which is configured to mate with one or more non-structural components, (ii) an internal passage feature which is configured to be inserted into a connecting feature of the corresponding node member, and (iii) one or more keying features formed from a mating interface with the corresponding node member.

公开(公告)号：US12251884B2

公开(公告)日：2025-03-18

申请号：US15582409

申请日：2017-04-28

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Eahab Nagi El Naga ,  John Russell Bucknell ,  Chor Yen Yap ,  Broc William TenHouten ,  Antonio Bernerd Martinez

IPC: B22F3/105 ,  B22F3/02 ,  B22F3/10 ,  B22F3/16 ,  B22F3/18 ,  B22F10/28 ,  B22F10/43 ,  B22F10/47 ,  B22F10/60 ,  B22F10/66 ,  B23K26/142 ,  B23K26/342 ,  B23K26/70 ,  B29C64/386 ,  B29C64/40 ,  B29C67/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B22F10/30 ,  B22F12/55 ,  B22F12/60

Abstract: Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include resonant structures that can be removed by applying a resonance frequency. Support structures can be formed to include structures configured to melt when electrical current is applied for easy removal.

公开(公告)号：US12194674B2

公开(公告)日：2025-01-14

申请号：US16792113

申请日：2020-02-14

Applicant: DIVERGENT TECHNOLOGIES, INC.

Inventor： Broc William TenHouten ,  Eahab Nagi El Naga ,  John Russell Bucknell

IPC: B29C64/393 ,  B29C64/129 ,  B29C64/153 ,  B29C64/209 ,  B29C64/255 ,  B29C64/268 ,  B29C64/295 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/10 ,  B33Y50/02

Abstract: A multi-material three-dimensional (3-D) powder bed fusion-based (PBF) printer is disclosed. In one aspect, the 3-D PBF includes a body, a controller coupled to the body, a plurality of cartridges coupled to a print nozzle, an energy source coupled to an upper surface of the body, a deflector for deflecting an energy beam from the energy source, and a build plate on which a build piece can be 3-D printed. Each cartridge may include a slurry in which a specific print material or alloy is suspended. A depositor may selectively deposit the slurry onto the build plate to form a plurality of consecutive layers. For a given layer or a given region thereof, the controller may selectively deposit different amounts of the slurry to produce an alloy having a desired composition. A heating element may be used to vaporize the solvent in the deposited slurry. Using the deflector, the energy source can fuse the regions to sinter the deposited material and in some embodiments, to vaporize the solvent prior to sintering. In other embodiments, the slurries may include different alloys that can be selectively distributed across the layers to form a build piece having desired material characteristics.