Dm3d Technology, LLC

Bhaskar Dutta

Mark David Lewan

Vijayavel Bagavath-Singh

Jason David Franceschina

Jyoti Mazumder

Harshad Natu

W Swenson

An improved laser weld process control system and method are provided. The system and method include a machine vision camera to detect a deviation between a pre-programmed laser beam toolpath and a gap centerpoint between first and second parts being welded together. The first and second parts are secured to a rotatable fixture, and the system and method cause the rotatable fixture to rotate through a corrective angle to bring the gap centerpoint into alignment with the laser beam toolpath, optionally in real time during the application of laser beam energy. The system and method can also correct for a vertical misalignment of the laser focal point due to rotation of the fixture by adjusting the vertical separation of the laser unit relative to the fixture.

Vision-based rotary part offset correction for weld toolpathing

An assembly for measuring metal powder material mass flow rate during direct metal deposition. A detection strip is placed in the gas-blown metal powder material flow path. The detection strip is fixed in one end and suspended at the other end. The flowing metal powder material particles induce displacement to the detection strip. A displacement measurement sensor measures the amount of displacement of the detection strip. The amount of displacement of the detection strip gives relationship to the amount of the metal powder material flowing in the metal powder material flow path. The detection strip and the sensor are connected to a housing with a metal powder material inlet port and metal powder material outlet port and includes internal features for smooth travel of metal powder material particles.

Powder material mass flow rate measuring apparatus for additive manufacturing

An assembly for rapid manufacturing of symmetrical objects by direct metal deposition is disclosed. A rotary stage provides rotational movement to an object supported by the stage around a central stage axis. Nozzles are spaced above the rotary stage for performing direct metal deposition for building an object supported by the stage. Each nozzle is independently moveable along a horizontal axis and independently pivotable, and combined, moveable along a vertical axis for providing symmetrical movement corresponding to a symmetrical deposition configuration of the object while the object is rotated around the central stage axis.

Apparatus for multi-nozzle metal additive manufacturing

An apparatus for performing direct material deposition upon a substrate for generating a three dimensional object includes a motion system for moving an head. The head includes a laser for generating a laser beam and a laser scanner for directing the laser beam at the substrate for generating a melt pool at the substrate. A nozzle delivers material into the melt pool generated by the laser beam for forming a bead of material upon the substrate. The laser scanner is cooperable with the motion system, which is moveable along a first path while the laser scanner is simultaneously moveable along a second path for progressively generating a bead of material deposited upon the substrate.

Nozzle with laser scanning head for direct metal deposition

A source of heat energy and a source of material for performing a material additive process upon the thin wall member is disclosed. A fixture is located relative to the thin wall element. The source of heat energy used for forming a joining member between the workpiece and the fixture to fixedly secure the fixture to the workpiece preventing the thin wall member from deforming when subject to the source of heat energy. A direct material additive process is upon the thin wall member adding material to the thin wall member to improve physical characteristics of the thin wall member. The joining member is mechanically removed from the workpiece after the work piece cools. A portion of the material is mechanically removed from the thin wall member to achieve desired dimensional characteristics.

Method of controlling distortion during material additive applications

A method of forming a valve seat of an engine head formed from a first composition includes forming a groove at a predetermined valve seat location of a bore defined by the engine head. A source of directed heat energy preheats at least the valve seat location to about a temperature of the melting point of the first composition with the source of directed heat energy. The source of directed heat energy is infused with a material having a second composition generating a melt pool upon the groove by direct metal deposition with the melt pool including the second composition. The second composition includes a heat conductivity generally equal to a heat conductivity of the first composition for providing efficient transfer of heat energy from the first composition to the second composition.

Method of manufacturing high-conductivity wear resistant surface on a soft substrate

Direct metal deposition (DMD) is used to fabricate knife edges with extended service life. A metal alloy powder is deposited along a blank and melted with a laser beam so that the powder solidifies into a strip of material having a hardness and/or wear resistance greater than that of the starting material. The piece is then finished to produce a sharp edge in the solidified material. The powder may be melted while it is being deposited, or it may be melted after being deposited. A slot or groove may be formed in the blank with the metal alloy powder being deposited into the slot or groove. A hardened steel alloy powder is deposited onto a mild steel blank. For example, a tool steel or vanadium steel powder may be deposited onto a 1018 steel blank. An invention line-beam nozzle may be used for deposition and/or powder melting.

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Troy, MI, United States of America

Bhaskar Dutta