公开(公告)号：US20190143451A1

公开(公告)日：2019-05-16

申请号：US15811313

申请日：2017-11-13

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin MAMRAK ,  MacKenzie Ryan REDDING

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y70/00 ,  B23K15/00 ,  B23K15/08 ,  B23K26/03 ,  B23K31/12 ,  B23K35/02

CPC classification number: B23K26/342 ,  B23K15/0086 ,  B23K15/08 ,  B23K26/03 ,  B23K26/032 ,  B23K26/034 ,  B23K26/0342 ,  B23K26/082 ,  B23K26/34 ,  B23K31/125 ,  B23K35/0255 ,  B23P15/00 ,  B23P2700/12 ,  B29C64/147 ,  B29C64/393 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  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, in-process monitoring, and closed loop control.

公开(公告)号：US20190134892A1

公开(公告)日：2019-05-09

申请号：US15807439

申请日：2017-11-08

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin MAMRAK ,  Zachary FIELDMAN

IPC: B29C64/153 ,  B29C64/393 ,  B22F3/105 ,  B33Y50/02 ,  B33Y30/00

Abstract: A method, apparatus, and program for calibrating an additive manufacturing apparatus. In one aspect, a method is disclosed for calibrating an additive manufacturing apparatus. The method includes forming a first solidified portion within a first scan region, wherein the solidified portion within the first scan region is formed by irradiating a build material while a build unit is in a first location. The method further includes forming a second solidified portion within a second scan region, wherein the second solidified portion within the second scan region is formed by irradiating a build material while a build unit is in a second location different from said first location. An alignment of the additive manufacturing apparatus determined based on the detected alignment of the first solidified portion and the second solidified portion.

公开(公告)号：US20190030606A1

公开(公告)日：2019-01-31

申请号：US15664861

申请日：2017-07-31

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin MAMRAK

IPC: B22F3/16 ,  B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y40/00

Abstract: The present disclosure generally relates to powder packing for additive manufacturing (AM) methods and systems. Conventional powder packing methods have focused on leveling the bulk powder cone in the powder reservoir. Moreover, such methods may be 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：US20190143444A1

公开(公告)日：2019-05-16

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 ,  B33Y70/00 ,  B23K15/08 ,  B23K26/082 ,  B23K26/342 ,  B23K35/02

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：US20180345600A1

公开(公告)日：2018-12-06

申请号：US15610113

申请日：2017-05-31

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Brandon HOLFORD ,  Jeffrey VAUGHT ,  MacKenzie Ryan REDDING ,  Justin MAMRAK

IPC: B29C67/00 ,  G05B19/18

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes one or more build units and a machining mechanism that are attached to a positioning mechanism, and a rotating build platform. The method involves at least rotating the build platform; repetitive cycles of moving the build unit(s) to deposit powder and irradiating at least a selected portion of the powder to form at least one fused layer to form at least one object and a build wall that retains unfused powder about the object; and removing the build wall by rotational machining.

公开(公告)号：US20180345373A1

公开(公告)日：2018-12-06

申请号：US15610214

申请日：2017-05-31

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Brandon HOLFORD ,  Jeffrey VAUGHT ,  MacKenzie Ryan REDDING ,  Justin MAMRAK

IPC: B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y80/00 ,  B33Y40/00 ,  B22F5/00 ,  B22F5/04 ,  B23K15/00 ,  B23K15/02 ,  B33Y50/02 ,  B23K26/342 ,  B23K26/70 ,  B23K26/08 ,  F01D25/24 ,  F23R3/00

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.

公开(公告)号：US20180345371A1

公开(公告)日：2018-12-06

申请号：US15610177

申请日：2017-05-31

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Justin MAMRAK ,  Jonathan ORTNER ,  MacKenzie Ryan REDDING

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

Abstract: An apparatus for powder-based additive manufacturing is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit is attached to a positioning mechanism that provides the build unit with independent movements in at least two dimensions. The build platform of the apparatus is rotating and preferably vertically stationary. Embodiments of the build unit that further includes a gas-flow mechanism and the build platform having a dynamically grown wall are also described. An additive manufacturing method using the apparatus involves rotating the build platform and repetitive cycles of moving the build unit(s) in a radial direction to deposit at least one layer of powder, and irradiating a selected portion of the powder to form a fused additive layer.

公开(公告)号：US20180281069A1

公开(公告)日：2018-10-04

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

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：US20180345378A1

公开(公告)日：2018-12-06

申请号：US15609747

申请日：2017-05-31

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Brandon HOLFORD ,  Jeffrey VAUGHT ,  MacKenzie Ryan REDDING ,  Justin MAMRAK

IPC: B22F3/24 ,  B33Y10/00 ,  B33Y30/00 ,  B22F3/105 ,  B33Y40/00

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.

公开(公告)号：US20180281068A1

公开(公告)日：2018-10-04

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

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.