Delavan Inc.

Rolls-Royce Corporation

Collins Engine Nozzles, Inc.

Matthew Donovan

Sergey Mironets

David H Bretz

Neal A Thomson

Thomas J Ocken

Philip E Buelow

Jason Allen Ryon

William Louis Wentland

Robert Bianco

Diana Giulietti

Joseph Samo

Kiley James Versluys

Andy W Tibbs

Brett A Pfeffer

Randall D Siders

Daniel Brindley

Danielle Douskey

Philip EO Buelow

Randall Siders

A contained radiation power metering system for measuring power of a radiation source of an additive manufacturing machine includes a base configured to fit within the additive manufacturing machine, a radiation sensor connected to the base and configured to receive radiation from the radiation source and output a radiation power signal, and a wireless module disposed on the base configured to receive the radiation power signal and transmit the radiation power signal from the system to a separate wireless receiver.

Power meter systems for additive manufacturing machines

An intake manifold for an additive manufacturing system includes a body defining a flow channel therein. The body includes an inlet end defining an inlet configured to intake gas and/or particles from a build area of the additive manufacturing system, and an outlet end defining an outlet that is fluidly connected to the inlet through the flow channel. The outlet is configured to be in fluid communication with an uptake manifold of the additive manufacturing system. The intake manifold also includes at least one mount extending from the outlet end of the body that is configured to rotatably mount the body to the uptake manifold.

Smoke and soot removal systems for additive manufacturing

A system for removing powder from an additively manufactured article includes a powder removal mechanism. The powder removal mechanism can include a build plate holder configured to hold a build plate at a distal end thereof. The powder removal mechanism can also include a first actuator that is configured to angle the build plate holder relative to gravity and a second actuator that is configured to rotate the build plate holder about a central axis of the build plate holder.

Systems and methods for post additive manufacturing processing

An air shroud for a nozzle includes an air shroud body defining an inlet and an outlet in fluid communication with one another to allow an outer airflow to issue therefrom. The air shroud also includes an air wipe disposed outboard of the air shroud body including a web defining a plurality of air wipe outlets in fluid communication with a downstream surface of the air shroud body such that air can flow through the air wipe outlets and wipe the downstream surface of the air shroud body. The air wipe can be integral with the air shroud body.

Air shrouds with air wipes

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 system for cleaning an additive manufacturing machine recoater includes a position module for sensing and/or determining a position of a recoater of the additive manufacturing machine and a gas manifold disposed in the additive manufacturing machine and configured to spray a pressurized gas on the recoater when the recoater is in at least one cleaning position. The system includes a valve configured to allow the pressurized gas to flow from a gas source to the gas manifold, and a valve control module configured to control the valve as a function of the position sensed and/or determined by the position module.

Recoater cleaning system

An air swirler has a radially outer wall bounding an annular passage. The radially outer wall has an axially extending portion and a radially convergent portion which converges towards an outlet of the passage. Downstream of the outlet, the passage facing surface of the radially outer wall becomes divergent. The region in which the passage facing surface of the radially outer wall is convergent then divergent defines the flare. A circumferential and axially extending recess is provided in the radially outer wall opposite the flare. A reinforcement of material with superior wear properties to the material of the main body is built in the recess to a radius which coincides with that of the outer surface of the axially extending portion of the radially outer wall. The reinforcement can conveniently be added to the main body by means of a laser consolidation ALM process.

Additive layer manufacturing for fuel injectors

A method for producing a device having at least one internal feature includes manufacturing an internal volume of the internal features out of a first material, disposing the internal volume in a parent material that has a higher melting point than the first material, causing the internal volume to melt within the parent material, and allowing at least a portion of the first material to diffuse into the parent material, thereby leaving behind the at least one internal feature within the parent material.

Flow devices and methods of making the same

A method for manufacturing a heat exchanger structure includes additively forming a top layer of a header after disposing a corrugated core within the header to retain the corrugated core within the header. Additively forming the top layer can include filling the corrugated core with powder until a suitable layer of powder overlays the corrugated core and the header and sintering the powder to form the top layer of the header.

Method for manufacturing a hybrid heat exchanger

A method includes additively manufacturing an article in an inert environment, removing the article from the inert environment and placing the article in a non-inert environment, allowing at least a portion the article to oxidize in the non-inert environment to form an oxidized layer on a surface of the article, and removing the oxidized layer (e.g., to smooth the surface of the article). The method can further include relieving stress in the article (e.g., via heating the article after additive manufacturing).

Additive manufacturing processing with oxidation

An air shroud for a nozzle includes an air shroud body defining an inlet and an outlet in fluid communication with one another to allow an outer airflow to issue therefrom, the air shroud body defining a downstream surface. A plurality of air wipe channels are defined within the air shroud body, wherein each of the plurality of air wipe channels is in fluid communication with at least one of a plurality of air wipe outlets and air wipe inlets. Each air wipe outlet is defined in the downstream surface of the air shroud body such that air can flow through each air wipe outlet and wipe the downstream surface of the air shroud body.

Air shrouds with improved air wiping

A fuel injector for a gas turbine engine includes a nozzle tip assembly having a substantially monolithically formed nozzle body. The nozzle body has an annular outlet chamber for issuing a spray from the nozzle tip. A feed channel is in fluid communication with the outlet chamber through a feed passage. A heat shield void substantially surrounds the feed channel(s).

Integrated heat shield

A method of fabricating a fuel injector is disclosed which includes the steps of forming a structural portion of a fuel injector from an alloy having a first mechanical property, and then adding an alloy having a second mechanical property on a surface area of the structural portion to enhance the mechanical properties of the fuel injector.

Growing community of inventors

Ankeny, IA, United States of America

Matthew Donovan