General Electric Company

Other

Michael Evans Graham

Thomas Charles Adcock

William Thomas Carter

John Broddus Deaton, Jr

Subhrajit Roychowdhury

John Joseph Madelone, Jr

Donnell Eugene Crear

Brian Scott McCarthy

John Dennis Jackson

Marshall Gordon Jones

Prabhjot Singh

David Charles Bogdan, Jr

Weiping Wang

Mark Allen Cheverton

Justin John Gambone, Jr

Mohammed Mounir Shalaby

Michael Robert Tucker

Lang Yuan

Victor Petrovich Ostroverkhov

Matthias Hoebel

James William Sears

Tao Jia

Kevin George Harding

Robert John Filkins

Michael Kent Cueman

Jason Harris Karp

Edward James Nieters

Emily Yixie Shu

Dean Michael Robinson

Felix Martin Gerhard Roerig

John Paul Davis

David Peter Mika

Charles Richard Evans

Pinghai Yang

Wenwu Zhang

Andrew David Deal

Juan Pablo Cilia

Jared Micheal Iverson

Meng-Ling Hsiao

Thomas Huei Hwang

Harry Kirk Mathews, Jr

Daniel Jason Erno

Apostolos Pavlos Karafillis

Arvind Rangarajan

Steven Charles Woods

Judson Sloan Marte

Jinjie Shi

Marc Thomas Edgar

Nathan Smith

Brock Estel Osborn

Gregory Alan Mohr

Thomas Etter

Mark Samuel Bailey

Andrew J Martin

Magdi Naim Azer

Garth M Nelson

Michael Charles Ostrowski

Andrea Marie Schmitz

Christopher James Kenny

Jessica Godin Karp

Dean Andrew Snelling, Jr

Richard Alan Ridilla

William Monaghan

Eric Edward Halla

Victor Manuel Perez Zarate

Brian Harlow Farrell

Paul S Stephens

John Knox Hinds

John Madelone

Justin John Gambone

Prashant Madhukar Kulkarni

Michelle Rene Bezdecny

Michael William Bailey

Timothy Mark Heitzman

Katherine Tharp Nowicki

Olalekan Solomon Odesanya

Michael J Paradis

Victor Petrovish Ostroverkhov

Brian Scott Mccarthy

Luis Gabriel De Alba Rivera

Michael Lee Bartholomew

Michelle René Bezdecny

John Broddus Deaton

David Charles Bogdan

David C Bogdan Jr

Jr John Broddus Deaton

Jr John Joseph Madelone

John Broddus Deaton Jr

John Joseph Madelone Jr

Jr Harry Kirk Mathews

David Charles Bogdan Jr

Justin John Gambone Jr

John Jackson

A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a calibration plane used for a first spatial calibration, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets. A method and a non-transitory medium are also disclosed.

Compensating laser alignment for irregularities in an additive manufacturing machine powderbed

A method of aligning at least one laser beam of an additive manufacturing arrangement. The method includes measuring a surface of the calibration plate at a plurality of measurement points using the coordinate measuring machine. The method further includes generating a correction field based on the plurality of measurement points using the coordinate measuring machine. The method further includes writing at least one fiducial mark on the surface of the calibration plate using the at least one laser beam. The method further includes generating calibration data for the surface of the calibration plate using the calibration system. The method also includes aligning the laser beam within the additive manufacturing system based on the calibration data and the correction field using the computing device by comparing a position of the fiducial mark from the calibration data with the correction field to determine a corrected position of the laser beam.

System and methods for compensating for calibration plate irregularities in additive manufacturing systems

A method of fabricating a component is provided. The method includes depositing particles onto a build platform. The method also includes distributing the particles to form a build layer. The method further includes operating a consolidation device to consolidate a first plurality of particles along a scan path to form a component. The component includes a top surface spaced apart from the build platform and an outer surface. The outer surface extends between the build platform and the top surface, and at least a portion of the outer surface faces a substantially particle-free region of the build platform.

Systems and methods for additive manufacturing

A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a reference plane containing the burn-paper when the fiducial marks were generated, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets. A method and a non-transitory medium are also disclosed.

An additive manufacturing system includes a build platform, a particulate dispenser assembly configured to dispense or remove particulate to or from the build platform, and a plurality of print heads each having at least one binder jet. The binder jets are configured to dispense at least one binder in varying densities onto the particulate in multiple locations to consolidate the particulate to form the component with a variable binder density throughout. The system also includes a plurality of arms extending at least partially across the build platform and supporting the print heads and at least one actuator assembly configured to rotate the print heads and/or the build platform about a rotation axis and move at least one of the print heads and the build platform in a build direction perpendicular to the build platform as part of a helical build process for the component.

Additive manufacturing systems and methods including rotating binder jet print head

In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.

Methods and systems for fabricating a component by consolidating a particulate include a build platform configured to receive a particulate, a particulate dispenser configured to deposit the particulate on the build platform, and at least one print head including at least one jet. The at least one print head is configured to dispense a binder through the at least one jet onto the particulate to consolidate at least a portion of the particulate and form a component. The methods and systems also include at least one actuator assembly configured to rotate at least one of the at least one print head and the build platform about a rotation axis extending through the build platform and move at least one of the at least one print head and the build platform in a build direction perpendicular to the build platform as part of a helical build process for the component.

According to some embodiments, system and methods are provided comprising generating a nominal computer-aided design (CAD) image of a component; producing a physical representation of the component from the nominal CAD image using an additive manufacturing (AM) process; measuring the physical component to obtain measurement data; determining a deviation between geometry associated with the nominal CAD image and the obtained measurement data; determining a compensation field for the deviation, if the deviation is outside of a tolerance threshold; modifying the nominal CAD image by the compensation field; and producing a physical representation of the component from the modified nominal CAD image. Numerous other aspects are provided.

System and method for distortion mitigation and compensation in additive manufacturing processes through B-spline hyperpatch field

An additive manufacturing system includes a build platform, a plurality of particles positioned on the build platform defining a build layer, a first and second region within the build layer, and at least one consolidation device. The first region and the second region each including a portion of the plurality of particles. The at least one consolidation device is configured to consolidate the plurality of particles within the build layer into a solid, consolidated portion of said build layer. The consolidation device is further configured to consolidate at least one of the plurality of particles within the build layer and the solid, consolidated portion of the build layer into a molten volume of transfer material. The consolidation device is further configured to transfer a portion of the molten volume of transfer material within the first region from the first region to the second region.

Systems and methods for lateral material transfer in additive manufacturing system

Some embodiments facilitate creation of an industrial asset item via an additive manufacturing process wherein motion is provided between a build plate and a print arm. A correction engine may receive, from an industrial asset item definition data store containing at least one electronic record defining the industrial asset item, the data defining the industrial asset item. A correction engine computer processor may then correct the motion provided between the build plate and the print arm such that the motion deviates from a path indicated by the data defining the industrial asset item. The three-dimension printer may be a rotary printer such that the build plate rotates about a vertical axis and moves along the vertical axis during printing. In these cases, a pre-compensation algorithm may be applied to correct the motion provided between the build plate and the print arm before transmitting data to the three-dimensional additive manufacturing printer.

Scan path correction for movements associated with an additive manufacturing machine

An additive manufacturing system includes a build platform, at least one first consolidation device, and at least one second consolidation device. The at least one first consolidation device is configured to direct at least one first energy beam to a first face of a component. The first face has a first orientation. The at least one second consolidation device is configured to simultaneously direct at least one second energy beam toward a second face of the component as the first consolidation device directs the at least one first energy beam toward the first face. The second face has a second orientation different from the first orientation.

Systems and methods for finishing additive manufacturing faces with different orientations

An additive manufacturing system configured to manufacture a component including scan strategies for efficient utilization of one or more laser arrays. The additive manufacturing system includes at least one laser device, each configured as a laser array, and a build platform. Each laser device is configured to generate a plurality of laser beams. The component is disposed on the build platform. The at least one laser device is configured to sweep across the component and the build platform in at least one of a radial direction, a circumferential direction or a modified zig-zag pattern and simultaneously operate the one or more of the plurality of individually operable laser beams corresponding to a pattern of the layer of a build to generate successive layers of a melted powdered material on the component and the build platform corresponding to the pattern of the layer of the build. A method of manufacturing a component with the additive manufacturing system is also disclosed.

Scan strategies for efficient utilization of laser arrays in direct metal laser melting (DMLM)

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

An additive manufacturing system includes a laser device, a build plate, and a scanning device. The laser device is configured to generate a laser beam with a variable intensity. The build plate is configured to support a powdered build material. The scanning device is configured to selectively direct the laser beam across the powdered build material to generate a melt pool on the build plate. The scanning device is configured to oscillate a spatial position of the laser beam while the laser device simultaneously modulates the intensity of the laser beam to facilitate reducing spatter and to facilitate reducing a temperature of the melt pool to reduce overheating of the melt pool.

Systems and methods for dynamic shaping of laser beam profiles in additive manufacturing

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Slingerlands, NY, United States of America

Michael Evans Graham