Hamilton Sundstrand Corporation

Delavan Inc.

Raytheon Technologies Corporation

Kiley James Versluys

Sergey Mironets

Tahany Ibrahim El-Wardany

Evan J Butcher

Diana Giulietti

Eric W Karlen

Colette Opsahl Fennessy

William Louis Wentland

Vijay Narayan Jagdale

Thomas J Ocken

Matthew Donovan

Ranadip Acharya

Daniel Brindley

Twelves Jr Wendell V

A method of making an article is disclosed involving determining a plurality of patterns of discrete sections for a plurality of layers of fusible material. According to the method, the patterns are determined having section boundaries that avoid alignment with section boundaries of other layer patterns among the plurality of patterns according to criteria specified for the article. Layers of fusible material are repeatedly fused with an energy beam applied in a scanning pattern to each of the discrete sections sequentially for each of the plurality of patterns in the plurality of layers.

Additive manufacturing method

A support structure for an additive manufacturing system includes a support body with a support body material and an interface disposed on the support body with an interface material. The interface material has a ductile-to-brittle transition temperature that is higher than the ductile-to-brittle temperature of the support body material for selectively fracturing the interface material to separate an additively manufactured article from the support body.

Support structures for additive manufacturing techniques

A powder container can include a body defining a chamber having a bulk opening, a moveable cover configured to selectively cover the bulk opening, and a hopper nozzle extending from the body and in fluid communication with the chamber configured to allow powder to exit or enter the chamber, the hopper nozzle being smaller than the bulk opening.

Powder container systems for additive manufacturing

A method includes placing an additively manufactured article having one or more internal channels in a non-reactive liquid to remove remainder powder from within the one or more internal channels, wherein the non-reactive liquid is a gas at room temperature and/or pressure. Placing the additively manufactured article in the non-reactive liquid includes can include placing the additively manufactured article in liquid nitrogen.

Powder removal systems

A method of producing a heat exchanger includes designing the heat exchanger to include a wall with a target thickness. A model is created relating process parameters to geometry of a single track melt pool and relating the single track melt pool geometry to a heat exchanger wall thickness. At least one variable process parameter is defined. The model, heat exchanger wall target thickness, and variable process parameters are used to identify a set of process parameters to produce the heat exchanger wall target thickness. The melt pool geometry is predicted based on the model and process parameters. The heat exchanger wall target thickness is predicted based on the melt pool geometry. The process parameters that will produce the heat exchanger wall target thickness are identified. The additive manufacturing process is controlled based upon the identified set of process parameters to create the heat exchanger wall target thickness.

Controlled thin wall thickness of heat exchangers through modeling of additive manufacturing process

A method includes receiving torque data of a powder recoater operatively connected to an additive manufacturing system. The torque data includes torque data of the recoater when the recoater traverses a build area. Receiving torque data includes receiving force data from a plurality of load cells, each load cell operatively associated with a blade segment of a recoater blade assembly. The method also includes determining a quality of one or more of an additive manufacturing process and/or product based on the torque data.

Additive manufacturing quality control systems

A method for forming a part includes: forming a first portion of the part at a first level; forming a second portion of the part at a second level; wherein forming the first and second portions includes exposing the first and second levels to a sintering process and portions of the first and second levels to an electron beam; causing a magnetorheological (MR) fluid to move into a passage inside the first and second portions; exposing the first and second portions to a magnetic field causing motion of particles in the MR fluid to move and break up sintered material in the passage; and removing some or all of the sintered material in the passage.

Powered removal for element formed by powder bed fusion additive manufacturing processes

A method includes issuing a state change fluid into an internal passage of an additively manufactured article and causing the state change fluid to change from a first state having a first viscosity to a second state that is either solid or has a second viscosity that is higher than the first viscosity within the internal passage. The method can also include causing the state change fluid to change back from the second state to the first state and flushing the state change fluid from the internal passage to remove residual powder from the additively manufactured article.

Powder removal

A cap for an additive manufacturing recoater rake includes a clip portion defining a slot configured to receive a side edge portion of a recoater rake, and an angled surface extending from the clip portion. The angled surface is configured to contain powder pushed by the recoater rake on the powder bed.

Rake systems for additive manufacturing systems

A method according to an exemplary aspect of the present disclosure, includes, among other things, at least partially filling a vessel with an abrasive fluid, pressurizing the abrasive fluid, and vibrating a component within the vessel. Further, the method includes gradually adjusting a rate material is removed from the component.

Growing community of inventors

Hartford, CT, United States of America

Kiley James Versluys