公开(公告)号：US20230381864A1

公开(公告)日：2023-11-30

申请号：US18448458

申请日：2023-08-11

Applicant: General Electric Company ,  Concept Laser GmbH

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

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

CPC classification number: B22F10/85 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B22F12/49 ,  B22F12/41 ,  B22F12/90 ,  B22F10/28

Abstract: An additive manufacturing machine includes an energy beam system configured to emit an energy beam utilized in an additive manufacturing process, and first and second 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 monitors one or more operating parameters of the additive manufacturing process. A light source is configured to emit an assessment beam that follows an optical path incident upon the first and second optical elements. One or more light sensors detect a reflected beam that is either internally reflected by the first optical element or reflectively propagated between the first and second optical elements. A control system determines, based at least in part on assessment data comprising data from the one or more light sensors, whether at least one of the first and second optical elements exhibits an optical anomaly.

公开(公告)号：US11745426B2

公开(公告)日：2023-09-05

申请号：US16761644

申请日：2018-11-02

Applicant: General Electric Company

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding ,  Thomas Graham Spears

IPC: B29C64/268 ,  B22F10/14 ,  B22F10/28 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B29C64/393 ,  B29C64/165 ,  B22F12/41 ,  B22F10/366 ,  B22F12/37 ,  B22F12/67 ,  B22F12/70

CPC classification number: B29C64/268 ,  B22F10/14 ,  B22F10/28 ,  B22F10/366 ,  B22F12/41 ,  B29C64/165 ,  B29C64/393 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B22F12/37 ,  B22F12/67 ,  B22F12/70

Abstract: A method, apparatus, and program for additive manufacturing. The additive manufacturing method may include solidifying at least a portion of a first layer (601) of build material (416) within a first scan region (902A). At least one of a build unit (400) and a build platform (310) may be moved to solidify at least a portion of the first layer (601) of build material (416) within a second scan region (902B). A second layer (602) of build material (416) may be provided over at least a portion of the first scan region (902A) and the second scan region (902B). A second layer (602) of build material (416) may be solidified within at least a portion of the third scan region (902C), the third scan region (902C) may at least partially overlap and may be offset with relation to the first scan region (902A).

公开(公告)号：US20220274166A1

公开(公告)日：2022-09-01

申请号：US17749823

申请日：2022-05-20

Applicant: General Electric Company

Inventor： Michelle Lynn Sloderbeck ,  Christopher Hall ,  Laura Banks ,  Tim Murphy ,  David Ploetz ,  Zachary Fieldman ,  Christopher C. Chapman ,  Emily Bautista ,  MacKenzie Ryan Redding

IPC: B22F3/093 ,  B22F3/03 ,  B33Y40/00 ,  B33Y80/00 ,  B33Y10/00 ,  B33Y30/00 ,  B30B11/02 ,  B22F12/00

Abstract: The present disclosure generally relates to powder packing for additive manufacturing (AM) methods and systems. Conventional powder packing methods are manual and non-standardized, and they result in operator fatigue and potentially product inconsistencies. Powder packing according to the present disclosure improves standardization and reduces turnaround time, with the potential to lower the cost of AM.

公开(公告)号：US20210283692A1

公开(公告)日：2021-09-16

申请号：US16332154

申请日：2017-12-07

Applicant: General Electric Company

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

IPC: B22F12/00 ,  B29C64/40 ,  B29C64/153

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：US11103928B2

公开(公告)日：2021-08-31

申请号：US16002041

申请日：2018-06-07

Applicant: GENERAL ELECTRIC COMPANY

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

IPC: B22F3/105 ,  B33Y30/00 ,  B23K26/08 ,  B23K15/00 ,  B33Y50/02 ,  B33Y10/00 ,  B23K26/342 ,  B23K26/14 ,  B23K37/02 ,  B22F12/00 ,  B23K26/082 ,  B23K26/00 ,  B23K26/12 ,  B29C64/153 ,  B29C64/371 ,  B33Y40/00 ,  B22F12/70 ,  B23K103/00 ,  B23K103/18 ,  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：US11014189B2

公开(公告)日：2021-05-25

申请号：US15990142

申请日：2018-05-25

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Rachel Wyn Levine ,  Christian Stevenson ,  Justin Mamrak ,  MacKenzie Ryan Redding

IPC: B23K15/00 ,  B33Y10/00 ,  B33Y50/02 ,  B23K26/342

Abstract: The present disclosure generally relates to methods of additive manufacturing with control of the energy beam incidence angle that allows for aligning the laser beam angle to directly oppose the building direction of an angled wall. The method includes building an object in an additive manufacturing powder bed where the object includes a surface that is defined by a build vector projecting outward relative to the build plate center at an angle Φ relative to normal of the build plate such that 90°>Φ>0° and the directed energy beam forms an angle θL2 relative to normal of the build plate such that 270°>θL2>180°, wherein θL2−Φ=180°±Δ, and Δ

公开(公告)号：US10894299B2

公开(公告)日：2021-01-19

申请号：US15811293

申请日：2017-11-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding ,  Thomas Graham Spears ,  Mark Kevin Meyer

IPC: B23K15/00 ,  B33Y10/00 ,  B33Y30/00 ,  B23K35/02 ,  B23K15/08 ,  B23K26/082 ,  B23K26/342 ,  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.

公开(公告)号：US10828723B2

公开(公告)日：2020-11-10

申请号：US15811313

申请日：2017-11-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding ,  Thomas Graham Spears

IPC: B23K26/342 ,  B23K26/03 ,  B23K31/12 ,  B23K35/02 ,  B23K15/00 ,  B23K15/08 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y70/00 ,  B29C64/147 ,  B23P15/00 ,  B23K26/082 ,  B23K26/34 ,  B29C64/393

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：US10821516B2

公开(公告)日：2020-11-03

申请号：US15996058

申请日：2018-06-01

Applicant: GENERAL ELECTRIC COMPANY

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

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

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：US20200261977A1

公开(公告)日：2020-08-20

申请号：US16761745

申请日：2018-11-02

Applicant: General Electric Company

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding

IPC: B22F3/105 ,  B33Y10/00 ,  B33Y50/02

Abstract: A method, apparatus, and program for additive manufacturing. In one aspect, the additive manufacturing method includes irradiating a build material (416) to form a first solidified portion within a first scan region (812A) using an irradiation source (401) of a build unit (400). At least one of the build unit and a build platform may be moved to irradiate a second scan region (812B), wherein an irradiation source (401) directing mechanism is adjusted to compensate for a misalignment between the first scan region and the second scan region (640).