Lawrence Livermore National Security, LLC

Seurat Technologies, Inc.

Other

Andrew James Bayramian

James A DeMuth

Francis Lawrence Leard

Bassem S El-Dasher

Drew W Kissinger

Ning Duanmu

James A Demuth

John Caird

Joseph Collin Farmer

Robert J Deri

Yiyu Shen

Susanne Kras

Kevin J Kramer

Alvin Charles Erlandson

Mary Louis Spaeth

Kenneth Rene Manes

Joseph Gillespie

Sharon G Torres

Cote LeBlanc

Eric B Duoss

Christopher M Spadaccini

Joshua D Kuntz

Kourosh Kamshad

Christopher Allen Ebbers

Jeffrey Jarboe

Al Erlandson

Alexander M Rubenchik

Kathleen Irene Schaffers

Steven James Telford

Rodney Kay Lanning

William A Molander

Harold W Chittick

April L Cooke

Nicholas C Ferreri

Robbert Van Der Bijl

Summer Kapuaimilia Mundon

J Thare MacDonald

Robin R Miles

Jeffery F Latkowski

Edward Ira Moses

Richard H Sawicki

Saad A Khairallah

Mark Rhodes

James P Armstrong

Thomas M Spinka

Mark A Henesian

Edward Steven Fulkerson, Jr

John Roehling

Joseph Arthur Menapace

Craig W Siders

Peter A Amendt

John C Post

Anthony Michael Dunne

Constantin L Haefner

Glenn Beer

Daniel C Mason

Thomas C Galvin

Charles L Heinbockel

Edward S Koh

Matthew Murachver

Thomas M Anklam

John Allyn Caird

John A Caird

Mark A Rhodes

Christopher A Ebbers

Alvin C Erlandson

An apparatus includes at least one laser source and a print bed. A light valve array having at least three optically addressable light valves is positioned to direct differing images at the print bed. Optics to direct multiple beams derived from the at least one laser source can be positioned to direct light toward and from the optically addressable light valves.

Distributed flux array

An additive manufacturing method supporting layer by layer testing includes a layer test including generating a hammer beam using laser light having a first wavelength, generating a read-out beam using laser light having a second wavelength, directing the generated hammer beam toward a first layer on a part to provide an acoustic hammer pulse that induces surface movement of the part, and reading the surface movement of the part using the read-out beam directed to a second position on the part. Layers can be added and the layer test repeated.

Additive manufacturing with photo-acoustic tomography defect testing

A cartridge for a manufacturing system includes a sealable chamber having a bed and a laser transparent window. A powder hopper can be positioned within the sealable chamber. A powder spreader is positioned within the sealable chamber for distributing powder from the powder hopper onto the bed.

Print cartridge for additive manufacturing

A manufacturing system includes a printer chamber having a printer bed that supports manufacturing materials and an internal heating system supported by the printer chamber. The internal heating systems is configured to direct patterned heat energy onto the printer bed and supported manufacturing materials. An external heating system is supported by or positioned near the printer chamber and configured to direct patterned heat energy onto the printer bed and any supported manufacturing materials.

Thermal compensation methods for laser energy delivery for additive manufacturing using heating and cooling elements

A print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge. A laser engine including a frame can be positioned to hold at least one removable field replaceable unit that includes at least some laser optics or patterning optics. An optical alignment system can be attached to at least one of the print station or the laser engine to align the field replaceable unit with respect to the removable cartridge.

Modular architecture for additive manufacturing

An additive manufacturing system having multiple components includes a high power laser to form a laser beam. A beam dump with a fluid chamber having at least one laser transparent window into which the laser beam is directed is provided. A heat exchanger is connected to the fluid chamber, with the heat exchanger acting to provide useful energy to at least one of the multiple components of the additive manufacturing system. An absorbing fluid can be circulated through both the fluid chamber and the heat exchanger.

Absorbing laser beam dump for high average-peak power laser systems

The present disclosure relates to a method involving a substrate having an interface layer, wherein the interface layer (IL) forms only an upper surface portion of the substrate, and a feedstock material (FM) placed on the IL. The method involves using a laser system to generate first and second beam components providing first and second power flux levels, respectively, where the second level is greater than the first. The FM is heated to a first level short of a melting point using the first beam component, at which point the particles of the FM begin to experience surface tension forces relative to the IL. Further heating the FM to a second level melts the FM and also melts the IL of the substrate, but where a portion of the IL remains unmelted by the second beam component as the particles of the FM and the IL are bonded together.

Laser pulse shaping for additive manufacturing

The present disclosure relates to systems and methods for performing large area laser powder bed fusion (LBPF) to form a plurality of layers of a 3D part in a layer-by-layer fashion using meltable powder particles. In one implementation the system makes use of a first light source, which may be a diode laser subsystem, for generating a first light pulse of a first duration. The first light is used to preheat a substrate underneath a new layer of powder particles, wherein the substrate is formed from a previously fused quantity of the powder particles. A second light source, which may be a pulse laser, generates a second light pulse subsequent to the first light pulse. The second light pulse has a second duration shorter than the first duration by a factor of at least about 10, and fully melts the new layer of powder particles in addition to the substrate, to achieve a smooth printed layer. The wavelength of the first light pulse also differs from a wavelength of the second light pulse.

System and method for large-area pulsed laser melting of metallic powder in a laser powder bed fusion application

A part defect testing system includes a hammer beam system that provides laser light having a first wavelength. A read-out beam system provides laser light having a second wavelength. A control system is used to direct the generated hammer beam laser light toward a first position on a part to provide an acoustic hammer pulse that induces surface movement of the part. An areal camera is arranged to produce an interferogram derived from reading surface movement of the part using the read-out beam directed to a second position on the part.

Photo-acoustic tomography defect testing system and method

The present disclosure relates to a system for performing an Additive Manufacturing (AM) fabrication process on a powdered material, deposited as a powder bed and forming a substrate. The system makes use of a laser for generating a laser beam, and an optical subsystem. The optical subsystem is configured to receive the laser beam and to generate an optical signal comprised of electromagnetic radiation sufficient to melt or sinter the powdered material. The optical subsystem uses a digitally controlled mask configured to pattern the optical signal as needed to melt select portions of a layer of the powdered material to form a layer of a 3D part. A power supply and at least one processor are also included for generating a plurality of different power density levels selectable based on a specific material composition, absorptivity and diameter of the powder particles, and a known thickness of the powder bed. The powdered material is used to form the 3D part in a sequential layer-by-layer process.

System and method for high power diode based additive manufacturing

In one embodiment a laser amplifier includes a light pump source that can generate light at a first wavelength or range of wavelengths. The laser amplifier further includes an optically pumped laser amplifier having a gain medium that amplifies light at a second wavelength or range of wavelengths in response to receiving generated light from the light pump source. A housing is used to at least partially surround the gain medium and hold a coolant fluid able to absorb the second wavelength or range of wavelengths.

Fluid edge cladding for spectroscopic absorption of laser emissions and amplified spontaneous emission

An additive manufacturing system includes a high power laser to form a high fluence laser beam at a first wavelength. The systems includes a 2D patternable light valve having a resonance based structure responsive to a write beam.

Resonance based light valve system

An additive manufacturing system includes a high power laser to form a high fluence laser beam at a first wavelength. A 2D patternable light valve having a phase change material responsive to a write beam at a second wavelength, and non-responsive at the first wavelength is used to pattern the high fluence laser beam.

Phase change light valve system

A method of additive manufacture is disclosed. The method can include providing an enclosure surrounding a powder bed and having an atmosphere including helium gas. A high flux laser beam is directed at a defined two dimensional region of the powder bed. Powder is melted and fused within the defined two dimensional region, with less than 50% by weight of the powder particles being displaced into any defined two dimensional region that shares an edge or corner with the defined two dimensional region where powder melting and fusing occurs.

Additive manufacturing system for object creation from powder using a high flux laser for two-dimensional printing

An additive manufacturing system includes a high power laser to form a laser beam directed against a light valve. An active light valve cooling system is arranged to remove heat from the light valve and a heat exchanger is connected to the active light valve cooling system. A heat exchange fluid is circulated through the active light valve cooling system and the heat exchanger.

Light valve cooling system

Growing community of inventors

Manteca, CA, United States of America

Andrew James Bayramian