公开(公告)号：US12076789B2

公开(公告)日：2024-09-03

申请号：US16332154

申请日：2017-12-07

Applicant: General Electric Company

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

IPC: B29C64/153 ,  B22F12/67 ,  B29C64/40 ,  B22F10/28 ,  B22F10/36 ,  B22F10/38 ,  B22F10/47 ,  B22F12/44 ,  B22F12/49 ,  B22F12/52 ,  B22F12/70 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y70/00

CPC classification number: B22F12/67 ,  B29C64/153 ,  B29C64/40 ,  B22F10/28 ,  B22F10/36 ,  B22F10/385 ,  B22F10/47 ,  B22F12/44 ,  B22F12/49 ,  B22F12/52 ,  B22F12/70 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y70/00 ,  Y02P10/25

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：US20240286343A1

公开(公告)日：2024-08-29

申请号：US18658111

申请日：2024-05-08

Applicant: General Electric Company

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding

IPC: B29C64/153 ,  B22F10/14 ,  B22F10/25 ,  B22F10/28 ,  B22F10/32 ,  B22F10/322 ,  B22F10/50 ,  B22F10/77 ,  B22F12/00 ,  B22F12/20 ,  B22F12/49 ,  B22F12/67 ,  B22F12/70 ,  B29C64/371 ,  B33Y10/00 ,  B33Y30/00

CPC classification number: B29C64/153 ,  B22F10/32 ,  B22F10/322 ,  B22F10/50 ,  B22F12/20 ,  B22F12/22 ,  B22F12/49 ,  B22F12/70 ,  B29C64/371 ,  B33Y10/00 ,  B33Y30/00 ,  B22F10/14 ,  B22F10/25 ,  B22F10/28 ,  B22F10/77 ,  B22F12/67 ,  B22F2201/02 ,  B22F2201/11

Abstract: An additive manufacturing machine includes a plurality of subsystems, such as a condensate evacuation subsystem for removing byproducts of the additive manufacturing products near a powder bed, a closed loop subsystem for cleaning contaminants from sensitive machine components, and/or an electronics cooling subsystem for cooling an electronics compartment. Each subsystem may include a dedicated gas circulation loop that is operably coupled to a gas circulation device for urging a clean flow of gas to each of the subsystems to perform a particular function.

公开(公告)号：US20230405926A1

公开(公告)日：2023-12-21

申请号：US18461890

申请日：2023-09-06

Applicant: General Electric Company

Inventor： Andrew Martin ,  Justin Mamrak

IPC: B29C64/241 ,  B29C64/153 ,  B29C64/268 ,  B29C64/188 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/245 ,  B29C64/371 ,  G05B19/4099 ,  B22F10/28 ,  B22F12/37 ,  B22F12/67

CPC classification number: B29C64/241 ,  B29C64/153 ,  B29C64/268 ,  B29C64/188 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/245 ,  B29C64/371 ,  G05B19/4099 ,  B22F10/28 ,  B22F12/37 ,  B22F12/67 ,  B22F2999/00 ,  B22F2201/00 ,  B22F12/49

Abstract: The additive manufacturing device includes a positioning mechanism configured to provide independent movement of a build unit in at least two dimensions. The build unit may include a gasflow device for providing a flow zone and an irradiation beam directing unit. The irradiation beam directing unit may form a first solidification line and form a second solidification line at an angle other than 0° and 180° with respect to the first solidification line. During the formation of the first solidification line, the build unit may be positioned in a first orientation such that the first direction of the flow zone is substantially perpendicular to the first solidification line. During the formation of the second solidification line, the build unit may be positioned in a second orientation such that the flow zone along the first direction is substantially perpendicular to the second solidification line.

公开(公告)号：US11780164B2

公开(公告)日：2023-10-10

申请号：US17397356

申请日：2021-08-09

Applicant: General Electric Company

Inventor： Andrew Martin ,  Justin Mamrak

IPC: B29C64/268 ,  B29C64/153 ,  B29C64/241 ,  B29C64/188 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/245 ,  B29C64/371 ,  G05B19/4099 ,  B22F10/28 ,  B22F12/37 ,  B22F12/67 ,  B22F12/49 ,  B22F12/52 ,  B22F12/70 ,  B22F10/32 ,  B22F10/366

CPC classification number: B29C64/241 ,  B22F10/28 ,  B22F12/37 ,  B22F12/67 ,  B29C64/153 ,  B29C64/188 ,  B29C64/245 ,  B29C64/268 ,  B29C64/371 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  G05B19/4099 ,  B22F10/32 ,  B22F10/366 ,  B22F12/49 ,  B22F12/52 ,  B22F12/70 ,  B22F2201/00 ,  B22F2999/00 ,  B22F2999/00 ,  B22F12/70 ,  B22F2201/00 ,  B22F2999/00 ,  B22F10/32 ,  B22F2201/00

Abstract: A method, apparatus, and program for additive manufacturing. The additive manufacturing device includes a positioning mechanism configured to provide independent movement of at least one build unit in at least two dimensions. The build unit may further include a gasflow device for providing a flow zone along a first direction with relation to the build unit. The build unit may further include a powder delivery mechanism and an irradiation beam directing unit. The irradiation bean unit may follow a first irradiation path, wherein the first irradiation path forms at least a first solidification line and at least a second solidification line formed at an angle other than 0° and 180° with respect to the first solidification line. During the formation of the first solidification line, the build unit may be positioned in a first orientation such that the first direction of the flow zone is substantially perpendicular to the first solidification line. During the formation of the second solidification line, the build unit may be positioned in a second orientation such that the flow zone along the first direction is substantially perpendicular to the second solidification line.

公开(公告)号：US11584073B2

公开(公告)日：2023-02-21

申请号：US16761623

申请日：2018-11-02

Applicant: General Electric Company

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding

IPC: B29C64/209 ,  B33Y30/00 ,  B29C64/214 ,  B29C64/364 ,  B29C64/268 ,  B29C64/165 ,  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：US11478853B2

公开(公告)日：2022-10-25

申请号：US15390089

申请日：2016-12-23

Applicant: General Electric Company

Inventor： Andrew J. Martin ,  Mackenzie Ryan Redding ,  Justin Mamrak

IPC: B22F3/105 ,  B33Y10/00 ,  B33Y50/02 ,  B23K26/342 ,  B23K26/70 ,  B23K26/042 ,  B22F10/20 ,  B23K15/00 ,  B29C64/371 ,  B23K26/06 ,  B23K26/14 ,  B23K26/082 ,  B23K26/03 ,  B23K26/12 ,  B23K26/00 ,  B29C64/393 ,  B29C64/153 ,  B22F10/30

Abstract: A method of monitoring an additive manufacturing process in which one or more energy beams are used to selectively fuse a powder to form a workpiece, in the presence of one or more plumes generated by interaction of the one or more energy beams with the powder. The method includes using at least one sensor to generate at least one signal representative of a trajectory of one or more of the plumes.

公开(公告)号：US20220331876A1

公开(公告)日：2022-10-20

申请号：US17232648

申请日：2021-04-16

Applicant: General Electric Company ,  Concept Laser GmbH

Inventor： Fabian Zeulner ,  Christian Dicken ,  Justin Mamrak ,  MacKenzie Ryan Redding ,  Bertram Gaerber

IPC: B22F10/85 ,  B33Y10/00 ,  B22F12/90 ,  B22F10/28 ,  B33Y30/00 ,  B22F12/41 ,  B22F12/49 ,  B33Y50/02

Abstract: An additive manufacturing machine may include an energy beam system configured to emit an energy beam utilized in an additive manufacturing process, and one or more optical elements utilized by, or defining a portion of, the energy beam system and/or an imaging system of the additive manufacturing machine. The imaging system may be configured to monitor one or more operating parameters of the additive manufacturing process. The additive manufacturing machine may include a light source configured to emit an assessment beam that follows an optical path incident upon the one or more optical elements, and one or more light sensors configured to detect a reflected beam comprising at least a portion of the assessment beam reflected and/or transmitted by at least one of the one or more optical elements. The additive manufacturing machine may include a control system configured to determine, based at least in part on assessment data comprising data from the one or more light sensors, whether the one or more optical elements exhibit an optical anomaly.

公开(公告)号：US20220111599A1

公开(公告)日：2022-04-14

申请号：US17070403

申请日：2020-10-14

Applicant: General Electric Company ,  Concept Laser GmbH

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding ,  Bertram Gaerber

IPC: B29C64/393 ,  B29C64/135 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: A method of operating an additive manufacturing machine may include determining an operational state and/or a remedial event for the machine based on optical anomalies on one or more optical elements of an energy beam system determined by image data from a light sensor that detects a reflected portion of an imaging beam reflected by the optical elements. The remedial event may include a maintenance event and/or a replacement event. An object may be additively manufactured using nominal operating conditions during a nominal operational state, and/or using one or more augmented operating conditions during an augmented operational state. A maintenance operation may be performed, such as cleaning and/or calibrating the one or more optical elements and/or one or more components of the energy beam system, upon having determined the remedial event that comprises the maintenance event. A replacement operation may be performed, such as replacing the one or more optical elements, upon having determined the remedial event that comprises the replacement event.

公开(公告)号：US11117320B2

公开(公告)日：2021-09-14

申请号：US15703600

申请日：2017-09-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Andrew Martin ,  Justin Mamrak

IPC: B29C64/268 ,  B29C64/153 ,  B29C64/241 ,  B29C64/188 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/245 ,  B29C64/371 ,  G05B19/4099 ,  B22F12/00 ,  B22F10/10

Abstract: A method, apparatus, and program for additive manufacturing. The additive manufacturing device includes a positioning mechanism configured to provide independent movement of at least one build unit in at least two dimensions. The build unit may further include a gasflow device for providing a flow zone along a first direction with relation to the build unit. The build unit may further include a powder delivery mechanism and an irradiation beam directing unit. The irradiation bean unit may follow a first irradiation path, wherein the first irradiation path forms at least a first solidification line and at least a second solidification line formed at an angle other than 0° and 180° with respect to the first solidification line. During the formation of the first solidification line, the build unit may be positioned in a first orientation such that the first direction of the flow zone is substantially perpendicular to the first solidification line. During the formation of the second solidification line, the build unit may be positioned in a second orientation such that the flow zone along the first direction is substantially perpendicular to the second solidification line.

公开(公告)号：US20210170494A1

公开(公告)日：2021-06-10

申请号：US16761632

申请日：2018-11-02

Applicant: General Electric Company

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding

IPC: B22F10/50 ,  B22F10/28 ,  B22F12/49 ,  B22F12/70 ,  B22F10/77 ,  B33Y10/00 ,  B33Y30/00

Abstract: An additive manufacturing machine (900) includes a plurality of subsystems, such as a condensate evacuation subsystem (940) for removing byproducts of the additive manufacturing products near a powder bed, a closed loop subsystem (960) for cleaning contaminants from sensitive machine components (964), and/or an electronics cooling subsystem (984) for cooling an electronics compartment (980). Each subsystem (940, 960, 984) may include a dedicated gas circulation loop (942, 966, 986) that is operably coupled to a gas circulation device (944, 968, 988) for urging a clean flow of gas (946, 962, 990) to each of the subsystems (940, 960, 984) to perform a particular function.