公开(公告)号：US20220032549A1

公开(公告)日：2022-02-03

申请号：US16943793

申请日：2020-07-30

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  Aymeric Moinet ,  Evan John Dozier ,  Sathyanarayanan Raghavan ,  Michael Evans Graham ,  Tyler Nathaniel Nelson ,  Rajesh Kartik Bollapragada

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

Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component. The model includes a plurality of elements and at least one region of interest. The control system is also configured to apply a strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile for at least one element of the plurality of elements. The build characteristic contribution profile represents an effect of the strain load applied to the at least one element on a build characteristic of at least one location within the at least one region of interest. The control system is further configured to adjust a build parameter for a location within the component relating to the at least one element of the plurality of elements based on the build characteristic contribution profile.

公开(公告)号：US20190240781A1

公开(公告)日：2019-08-08

申请号：US15888727

申请日：2018-02-05

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Todd Jay Rockstroh ,  Brian Scott McCarthy ,  Subhrajit Roychowdhury ,  Younkoo Jeong ,  David Charles Bogdan, JR.

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B23K26/082 ,  B23K26/08 ,  B23K26/06 ,  B23K26/144 ,  B23K26/16

CPC classification number: B23K26/342 ,  B23K26/0608 ,  B23K26/082 ,  B23K26/0823 ,  B23K26/144 ,  B23K26/16 ,  B33Y10/00 ,  B33Y30/00

Abstract: A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.

公开(公告)号：US20240017481A1

公开(公告)日：2024-01-18

申请号：US17865489

申请日：2022-07-15

Applicant: General Electric Company

Inventor： Victor Petrovich Ostroverkhov ,  Christopher Darby Immer ,  Thomas Charles Adcock ,  Justin John Gambone ,  Daniel Jason Erno ,  Brian Scott McCarthy ,  John Joseph Madelone, JR.

IPC: B29C64/153 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/282 ,  B29C64/268 ,  B28B1/00 ,  B22F10/28 ,  B22F12/45

CPC classification number: B29C64/153 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/282 ,  B29C64/268 ,  B28B1/001 ,  B22F10/28 ,  B22F12/45

Abstract: Methods of additively manufacturing a three-dimensional object include irradiating a first build plane region using a first energy beam defining a beam diameter, the first energy beam travelling along a first oscillating path in a first direction to consolidate a first wall defining a thickness perpendicular to the first direction, wherein a build material adjacent a first side of the first wall and the build material adjacent a second side of the first wall, opposite the first side of the first wall, remains unconsolidated; and wherein the thickness of the first wall is greater than the beam diameter.

公开(公告)号：US11679551B2

公开(公告)日：2023-06-20

申请号：US16289076

申请日：2019-02-28

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  Dean Andrew Snelling, Jr. ,  Thomas Adcock ,  Donnell Crear ,  Michael Evans Graham

IPC: B33Y50/02 ,  B29C64/153 ,  B29C64/393 ,  B29C64/268 ,  B22F10/20 ,  B22F12/90 ,  B22F10/31 ,  B33Y10/00 ,  B33Y30/00 ,  B22F12/45 ,  B22F12/49 ,  B22F12/60

CPC classification number: B33Y50/02 ,  B22F10/20 ,  B22F10/31 ,  B22F12/90 ,  B29C64/153 ,  B29C64/268 ,  B29C64/393 ,  B22F12/45 ,  B22F12/49 ,  B22F12/60 ,  B33Y10/00 ,  B33Y30/00

Abstract: A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a reference plane containing the burn-paper when the fiducial marks were generated, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets. A method and a non-transitory medium are also disclosed.

公开(公告)号：US11407170B2

公开(公告)日：2022-08-09

申请号：US16722517

申请日：2019-12-20

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  John Joseph Madelone, Jr. ,  Justin John Gambone, Jr. ,  Rachel Wyn Levine

IPC: B29C64/393 ,  B29C64/153 ,  B29C64/282 ,  B29C64/245 ,  B29C64/255 ,  B29C64/268 ,  B33Y10/00 ,  B33Y30/00

Abstract: An additive manufacturing system includes a first laser device configured to generate a first laser beam and a second laser device configured to generate a second laser beam. The laser scanning devices include a first laser scanning device and a second laser scanning device. The first laser scanning device is configured to selectively direct the first laser beam from the first laser devices across a powder bed along a plurality of first hatching paths and a first contour path along a contour of the solid component. The second laser scanning device is configured to selectively direct the second laser beam from the second laser devices across the powder bed along a plurality of second hatching paths and a second contour path along the contour of the solid component. The first contour path includes a first hook extending into the plurality of second hatching paths.

公开(公告)号：US20230278282A1

公开(公告)日：2023-09-07

申请号：US18317437

申请日：2023-05-15

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  Dean Andrew Snelling, JR. ,  Thomas Adcock ,  Donnell Crear ,  Michael Evans Graham

IPC: B29C64/153 ,  B33Y50/02 ,  B29C64/393 ,  B29C64/268 ,  B22F10/20 ,  B22F12/90 ,  B22F10/31

CPC classification number: B29C64/153 ,  B33Y50/02 ,  B29C64/393 ,  B29C64/268 ,  B22F10/20 ,  B22F12/90 ,  B22F10/31 ,  B33Y10/00

Abstract: A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a calibration plane used for a first spatial calibration, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets. A method and a non-transitory medium are also disclosed.

公开(公告)号：US20210187830A1

公开(公告)日：2021-06-24

申请号：US16722517

申请日：2019-12-20

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  John Joseph Madelone, JR. ,  Justin John Gambone, JR. ,  Rachel Wyn Levine

IPC: B29C64/153 ,  B29C64/268 ,  B29C64/282 ,  B29C64/245 ,  B29C64/255

Abstract: An additive manufacturing system includes a first laser device configured to generate a first laser beam and a second laser device configured to generate a second laser beam. The laser scanning devices include a first laser scanning device and a second laser scanning device. The first laser scanning device is configured to selectively direct the first laser beam from the first laser devices across a powder bed along a plurality of first hatching paths and a first contour path along a contour of the solid component. The second laser scanning device is configured to selectively direct the second laser beam from the second laser devices across the powder bed along a plurality of second hatching paths and a second contour path along the contour of the solid component. The first contour path includes a first hook extending into the plurality of second hatching paths.

公开(公告)号：US20210016394A1

公开(公告)日：2021-01-21

申请号：US16515470

申请日：2019-07-18

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  Eric Edward Halla ,  Thomas Charles Adcock ,  Michael Evans Graham ,  Andrea Marie Schmitz ,  Mark Samuel Bailey

IPC: B23K26/342 ,  B33Y30/00 ,  B33Y50/02 ,  B23K26/042 ,  B23K26/08 ,  B23K26/70

Abstract: A method of aligning at least one laser beam of an additive manufacturing arrangement. The method includes measuring a surface of the calibration plate at a plurality of measurement points using the coordinate measuring machine. The method further includes generating a correction field based on the plurality of measurement points using the coordinate measuring machine. The method further includes writing at least one fiducial mark on the surface of the calibration plate using the at least one laser beam. The method further includes generating calibration data for the surface of the calibration plate using the calibration system. The method also includes aligning the laser beam within the additive manufacturing system based on the calibration data and the correction field using the computing device by comparing a position of the fiducial mark from the calibration data with the correction field to determine a corrected position of the laser beam.

公开(公告)号：US20240326129A1

公开(公告)日：2024-10-03

申请号：US18739067

申请日：2024-06-10

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  Aymeric Moinet ,  Rajesh Kartik Bollapragada ,  Tyler Nathaniel Nelson

IPC: B22F10/00 ,  B22F10/10 ,  B22F10/80 ,  B22F12/49 ,  B29C64/386 ,  B33Y10/00 ,  B33Y50/00 ,  B33Y50/02

CPC classification number: B22F10/00 ,  B22F10/80 ,  B22F12/49 ,  B29C64/386 ,  B33Y50/00 ,  B22F10/10 ,  B33Y10/00 ,  B33Y50/02

Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component including a plurality of elements and at least one region of interest. The control system is also configured to apply at least one strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile based on the at least one strain load. The control system is further configured to determine a build parameter based at least partly on the build characteristic contribution profile.

公开(公告)号：US20220032367A1

公开(公告)日：2022-02-03

申请号：US16943799

申请日：2020-07-31

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  Aymeric Moinet ,  Rajesh Kartik Bollapragada ,  Tyler Nathaniel Nelson

IPC: B22F3/105

Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component including a plurality of elements and at least one region of interest. The control system is also configured to apply at least one strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile based on the at least one strain load. The control system is further configured to determine a build parameter based at least partly on the build characteristic contribution profile.