Georgia Tech Research Corporation

University of Michigan

Other

University of Texas System

Ddm Systems, Inc.

Suman Das

Dajun Yuan

Paul Cilino

Anirudh Rudraraju

Joseph Jefferson Beaman, Jr

John William Halloran

Rohan Bansal

Justin Gambone

Zhong Lin Wang

Scott J Hollister

Timothy Fuesting

Lawrence E Brown

Paul Krebsbach

Sheng Xu

Wenzhuo Wu

Yaguang Wei

Marvin Kilgo

Rui Guo

James K Santosa

A system including: a container for holding a photosensitive medium adapted to change states upon exposure to a light source; an optical imaging system, configured to move above the container holding the photosensitive medium, and having the light source; and a control system configured to: slice a digital model of a three-dimensional object into a slice having a cross section; generate a build cross section by filling a two-dimensional image with one or more copies of the cross section; add to the build cross section a conformal lattice to fill space in the build cross section around the one or more copies of the cross section; and control movement of the optical imaging system above the container to cure a portion of the photosensitive medium corresponding to the build cross section to produce a layer of a three-dimensional object.

Systems and methods for fabricating three-dimensional objects

Aspects of the disclosed technology include an additive manufacturing method including: applying a mixture of metal powder and a carrier agent to a substrate; removing a portion of the carrier agent from the applied mixture; and fusing the metal powder remaining in the applied mixture to the substrate.

Conformal material and support structures for additive manufacturing systems and methods of use thereof

Scanning Laser Epitaxy (SLE) is a layer-by-layer additive manufacturing process that allows for the fabrication of three-dimensional objects with specified microstructure through the controlled melting and re-solidification of a metal powders placed atop a base substrate. SLE can be used to repair single crystal (SX) turbine airfoils, for example, as well as the manufacture functionally graded turbine components. The SLE process is capable of creating equiaxed, directionally solidified, and SX structures. Real-time feedback control schemes based upon an offline model can be used both to create specified defect free microstructures and to improve the repeatability of the process. Control schemes can be used based upon temperature data feedback provided at high frame rate by a thermal imaging camera as well as a melt-pool viewing video microscope. A real-time control scheme can deliver the capability of creating engine ready net shape turbine components from raw powder material.

Systems and methods for additive manufacturing and repair of metal components

Systems and methods for fabricating three-dimensional objects. The system includes an optical imaging system providing a light source; a photosensitive medium adapted to change states upon exposure to a portion of the light source from the optical imaging system; a control system for controlling movement of the optical imaging system, wherein the optical imaging system moves continuously above the photosensitive medium. The method includes moving a maskless optical imaging system providing the light beam in a continuous sequence; presenting the light beam on a portion of the photosensitive medium; lowering a plate upon which the photosensitive medium resides; and applying a new layer of the photosensitive medium.

Systems and methods for fabricating three-dimensional objects are disclosed. The system includes an optical imaging system providing a light source; a photosensitive medium adapted to change states upon exposure to a portion of the light source from the optical imaging system; a control system for controlling movement of the optical imaging system, wherein the optical imaging system moves continuously above the photosensitive medium. The method includes moving a maskless optical imaging system providing the light beam in a continuous sequence; presenting the light beam on a portion of the photosensitive medium; lowering a plate upon which the photosensitive medium resides; and applying a new layer of the photosensitive medium.

In a method for growing a nanowire array, a photoresist layer is placed onto a nanowire growth layer configured for growing nanowires therefrom. The photoresist layer is exposed to a coherent light interference pattern that includes periodically alternately spaced dark bands and light bands along a first orientation. The photoresist layer exposed to the coherent light interference pattern along a second orientation, transverse to the first orientation. The photoresist layer developed so as to remove photoresist from areas corresponding to areas of intersection of the dark bands of the interference pattern along the first orientation and the dark bands of the interference pattern along the second orientation, thereby leaving an ordered array of holes passing through the photoresist layer. The photoresist layer and the nanowire growth layer are placed into a nanowire growth environment, thereby growing nanowires from the nanowire growth layer through the array of holes.

Large-scale fabrication of vertically aligned ZnO nanowire arrays

A selective laser sintering technique and system are provided for producing a heterogeneous product. The selective laser sintering technique and system is generally comprised of generating a computer model of the product and processing the model to obtain numerous cross-sectional representations of the model. The cross-sectional representations are manufactured layer by layer to create the product. Specifically, numerous different powders having a variety of properties are placed within nozzles positioned above a deposition bed using a hopper. Using the computer model as a guide, the different powders are placed at different positions on the deposition bed to form each layer of the device. The deposited powders are consolidated, micromachined, and milled using one or more lasers to create the product. Using this selective laser sintering technique a wide variety of heterogenous products may be produced, such as the following: 1) bio-implants, 2) small scale energy production, storage and conversion devices, 3) devices that exploit anomalous material behavior, and 4) nanocomposites.

Solid freeform fabrication of structurally engineered multifunctional devices

A method of fabricating a fully dense, three dimensional object by direct laser sintering is disclosed. In a chamber with a partial pressure atmosphere, a beam of directed energy melts metallic powder in order to form a solid layer cross section. Another layer of powder is deposited and melted, along with a portion of the previous layer. The energy beam typically is in the form of a laser, scanning along a path resembling a parametric curve or another, arbitrary piecewise parametric curve. In another embodiment, the previous layer is not remelted, thus creating an oxide film that acts as a clean stop to prevent unwanted downward growth.

Direct selective laser sintering of metals

The present invention relates to a method an apparatus for fabricating a component by a direct laser process. One form of the present invention contemplates a gas turbine engine blade having an abrasive tip formed directly thereon.

Growing community of inventors

Atlanta, GA, United States of America

Suman Das