General Electric Company

Sabic Innovative Plastics IP B.v.

Sabic Global Technolgoies B.v.

Mark Allen Cheverton

Victor Petrovich Ostroverkhov

John Broddus Deaton, Jr

Prabhjot Singh

Michael Evans Graham

Guanghua Wang

William Thomas Carter

Joseph John Shiang

Anant Achyut Setlur

Gary Charles Davis

Robert William Tait

Kevin Patrick Capaldo

Kevin George Harding

Marshall Gordon Jones

Xiaolei Shi

Brian Lee Lawrence

Michael Francis Xavier Gigliotti, Jr

Zhiyuan Ren

Mark Kevin Meyer

Kenneth Brakeley Welles

Harry Kirk Mathews, Jr

Venkat Subramaniam Venkataramani

Eugene Pauling Boden

Michael Francis Xavier Gigliotti

Thomas Charles Adcock

Todd Jay Rockstroh

James Anthony Brewer

Matthew Frank Niemeyer

Dennis Joseph Coyle

Christopher Allen Nafis

Pradeep Jeevaji Nadkarni

Shantaram Narayan Naik

Andrew A Burns

Sumeet Jain

Michael Teruki Takemori

Andrew David Deal

Jeffrey Joseph Popielarczyk

Marie Ann McMasters

Ruediger Soeren Kusch

Michael John Davis

Pinghai Yang

Vicki Herzl Watkins

Masako Yamada

Kiran Arunkumar Puthamane

Daniel Curtis Gray

James Gerard Lopez

Vinodkumar Vasudevan

Samar Jyoti Kalita

Sora Kim

Amitabh Bansal

Richard Brownell Arthur

Moitreyee Sinha

Russell Dennison

Chung-hei Simon Yeung

Sameer Kirti Talsania

Smara Jyoti Kalita

Michael T Takemori

John Broddus Deaton

Jr Michael Francis Xavier Gigliotti

Jr John Broddus Deaton

Jr Harry Kirk Mathews

Vicki H Watkins

The disclosure relates to an apparatus for manufacturing a metallic component, and corresponding methods. The apparatus may include a build plate with a build surface and an aperture. The apparatus may also include an actuator operable to translate a metallic component such that an end portion of the metallic component is positioned within the aperture of the build plate and below the build surface. The apparatus may further include a seal coupled within the aperture of the build plate and configured to engage the end portion of the metallic component. The aperture of the build plate, the seal, and the end portion of the metallic component may cooperate to form a powder bed to hold metallic powder therein. The apparatus may also include an external heat control mechanism operable to form a predetermined temperature profile of the end portion of the component to prevent cracking of the component.

Powder-bed additive manufacturing devices and methods

A direct metal laser melting (DMLM) system for enhancing build parameters of a DMLM component includes a confocal optical system configured to measure at least one of a melt pool size and a melt pool temperature. The DMLM system further includes a computing device configured to receive at least one of the melt pool size or the melt pool temperature from the confocal optical system. Furthermore, the DMLM system includes a controller configured to control the operation of a laser device based on at least one build parameter.

System and methods for enhancing the build parameters of a component

A method that includes additively manufacturing with an additive manufacturing (AM) system a sub-component that has a locator element. Using a control system of the AM system for positioning a first location of the locator element. Selectively placing a portion of another sub-component adjacent to the locator element, based on the positioning. Then attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning knowledge from the control system so as to make a component. A component that comprises a first sub-component that has an AM locator element; and a second sub-component attached to the first sub-component, wherein the locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.

Additively manufactured component with locator element for aligning sub-components

An additive manufacturing system includes a surface holding a particulate and a focused energy source configured to generate at least one beam that moves along the surface to heat the particulate to a melting point creating a melt path. A camera is configured to generate an image of the surface as the at least one beam moves along the surface. The camera has a field of view and is positioned in relation to the surface such that the field of view encompasses a portion of the melt path defining a plurality of rasters. The camera generates a time exposure image of at least the portion of the melt path defining the plurality of rasters.

Additive manufacturing systems including an imaging device and methods of operating such systems

An additive manufacturing system includes a laser device, a first scanning device, and an optical system. The laser device is configured to generate a laser beam, and the first scanning device is configured to selectively direct the laser beam across a powder bed. The laser beam generates a melt pool in the powder bed. The optical system includes an optical detector configured to detect electromagnetic radiation generated by the melt pool, and a second scanning device configured to direct electromagnetic radiation generated by the melt pool to the optical detector.

Systems and methods for monitoring a melt pool using a dedicated scanning device

A method of creating an article of manufacture is provided, which includes directing multiple laser beams to a single galvanometer; and dynamically repositioning the multiple laser beams in counterpart paths using the single galvanometer to shine the multiple laser beams on and melt a first powder material and, upon solidification of the melted first powder material, forming a first series of duplicate three dimensional structures, where each of the multiple laser beams is used to form at least one of the first series of duplicate three dimensional structures.

Parallel direct metal laser melting

A direct metal laser melting (DMLM) system includes a laser device configured to generate a melt pool in a powder bed based on a build parameter. In addition, the DMLM system includes a confocal optical system directed at the melt pool and configured to receive an optical signal emitted by the melt pool. The DMLM system further includes an optical sensor operatively coupled to the confocal optical system that is configured to receive the optical signal and to generate an electrical signal in response to the optical signal. A computing device is configured to receive the electrical signal from the optical sensor and to generate a control signal in response. The control signal is configured to modify the build parameter of the direct metal laser melting system in real-time to adjust at least one of a melt pool size and a melt pool temperature to achieve a desired physical property of the component.

System and methods for real-time enhancement of build parameters of a component

Method for additively manufacturing component and component made therefrom

Systems, apparatus and methods provide a visual representation to users of data collected from a three dimensional manufacturing process, such as an additive manufacturing (AM) process. In an embodiment, a user device receives process data associated with a three dimensional manufacturing process, transforms the process data into visualization data compatible with a computer-aided design specification, receives a Boolean query, and then renders, in response to the Boolean query, a visual depiction on a display screen of at least one aspect of the three dimensional manufacturing process and/or the three dimensional manufacturing apparatus and/or a object being manufactured.

Visualization of additive manufacturing process data

A method of monitoring a surface temperature of a hot gas path component includes directing an excitation beam having an excitation wavelength at a layer of a sensor material composition deposited on a hot gas path component to induce a fluorescent radiation. The method includes measuring fluorescent radiation emitted by the sensor material composition. The fluorescent radiation includes at least a first intensity at a first wavelength and a second intensity at a second wavelength. The surface temperature of the hot gas path component is determined based on a ratio of the first intensity at the first wavelength and the second intensity at the second wavelength of the fluorescent radiation emitted by the sensor material composition.

Methods for monitoring strain and temperature in a hot gas path component

A system for fabricating a component includes an additive manufacturing device and a computing device. The additive manufacturing device is configured to fabricate a first component by sequentially forming a plurality of superposed layers based upon a nominal digital representation of a second component, which includes a plurality of nominal digital two-dimensional cross-sections, each corresponding to a layer of the first component. The computing device includes a processor, wherein for an ilayer of the first component, the processor is configured to (a) generate a cumulative compensation transformation; (b) apply the cumulative compensation transformation to the nominal digital two-dimensional cross-section corresponding to the ilayer to create an intermediate digital two-dimensional cross-section corresponding to the ilayer; (c) determine a local compensation transformation; and (d) apply the local compensation transformation to the intermediate digital two-dimensional cross-section corresponding to the ilayer.

Systems and methods for creating compensated digital representations for use in additive manufacturing processes

A method for assessment of operational performance of a 3D manufacturing apparatus is provided. Images are obtained, in real-time during a 3D polymer printing build process in which at least one structure is built by the 3D manufacturing apparatus, the images being of an area of a build platform on which the at least one structure is built. The obtained images are evaluating, and it is determined, based on the evaluating, whether an operational flaw with the 3D manufacturing apparatus has occurred. Operational flaws include errors in the operation of the 3D manufacturing apparatus and/or component thereof, as evidenced by, for instance, distortions or other errors in the structure(s) being built and/or materials being used.

Operational performance assessment of additive manufacturing

A system and method for monitoring system including a embedded sensor coupled to an article, wherein the embedded sensor is a direct write embedded sensor using a high temperature light emitting material. A camera system detects illumination signals from the embedded sensors. A processing section processes the illumination signals and determines gas/surface temperatures and strain data for the article.

Method and system for multi-functional embedded sensors

Growing community of inventors

Mechanicville, NY, United States of America

Mark Allen Cheverton