公开(公告)号：US10960603B2

公开(公告)日：2021-03-30

申请号：US15711808

申请日：2017-09-21

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Lucas Jones ,  Justin Mamrak

IPC: B29C64/135 ,  B22F3/105 ,  B33Y50/02 ,  B23K26/082 ,  B22F3/00 ,  G03F7/00 ,  B33Y50/00 ,  B29C64/386 ,  B29C64/236 ,  B29C64/153 ,  B29C64/264 ,  B33Y10/00 ,  B29C64/241

Abstract: A method, apparatus, and program for additive manufacturing. In one aspect, the method and program comprises forming an at least partially solidified portion within a first scan region by irradiating a build material at a first energy density value along a first irradiation path. A second at least partially solidified portion is formed within a second scan region that is spaced with respect to the first scan region, wherein the solidified portion within the first scan region is formed by irradiation a build material at a second energy density value along a second irradiation path. The space between the first scan region and the second scan region is at least partially solidified by irradiating a build material at a third energy density value that less than the first energy density value and the second energy density value.

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).

公开(公告)号：US20200254691A1

公开(公告)日：2020-08-13

申请号：US16761754

申请日：2018-11-06

Applicant: General Electric Company

Inventor： Justin Mamrak ,  MacKenzie Ryan Redding ,  Jordan Maxine Shoemaker ,  Michael Thomas Gansler

IPC: B29C64/357 ,  B22F3/105 ,  B29C64/165 ,  B29C64/35 ,  B33Y30/00

Abstract: An additive manufacturing machine (910) includes a build unit (920) comprising a powder dispenser (906) including a hopper (1004) for receiving a volume of additive powder (1006). A powder supply system (1000) includes a powder supply source (1010) for providing additive powder (1006) into the hopper (1004) during a refill process. A powder reclamation system (1002) includes a vacuum pump (1030) coupled to a vacuum duct (1034, 1036) defining a suction inlet (1040) positioned for collecting misdirected additive powder (1006) dispensed during the refill process. A return duct (1038) includes a filter mechanism (1050) may filter and return the collected additive powder (1006) back to the powder supply source (1010) for reuse.

公开(公告)号：US20200254522A1

公开(公告)日：2020-08-13

申请号：US16761722

申请日：2018-11-02

Applicant: General Electric Company

Inventor： MacKenzie Ryan Redding ,  Justin Mamrak

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

Abstract: The present disclosure generally relates to methods and apparatuses (200) for additive manufacturing with improved powder (702) distribution capabilities. One aspect involves a mobile build unit (700) that can be moved around in two to three dimensions by a positioning system, to build separate portions of an object, such as a large object. The mobile build unit (700) may be used with an energy directing device (712) that directs irradiation onto a powder (702) layer. In the case of laser irradiation, the mobile build unit (700) may be used with a gasflow device (713A, 713B) that provides laminar gas flow to a laminar flow zone (714) above the layer of powder (703). The mobile build unit (700) of the present disclosure also has a recoater (705) concentrically surrounding a mobile build area, the re-coater (705) allowing the mobile build unit (700) to selectively deposit particular quantities of powder (702) in specific locations over a work surface in order to build large, high quality, high precision objects.

公开(公告)号：US20190134891A1

公开(公告)日：2019-05-09

申请号：US15807434

申请日：2017-11-08

Applicant: GENERAL ELECTRIC COMPANY

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

IPC: B29C64/153 ,  B22F3/105 ,  B29C64/273 ,  B23K26/144 ,  B29C64/386 ,  B29C64/245

Abstract: A method of fabricating an object by additive manufacturing is provided. The method includes measuring a build surface for building the object, determining which areas of the build surface are depressed, and initiating a build of the object at one of the depressed areas of the build surface. The initial building includes the steps of depositing a given layer of powder at the one depressed area of the build surface, fusing the given layer of powder at the one depressed area, and depositing a subsequent layer of powder at the one depressed area. The steps are repeating until the build surface is at a layer that is unified across the build surface.