General Electric Company

Other

William Thomas Carter

Mark Gilbert Benz

Bruce Alan Knudsen

Robert John Zabala

David Charles Bogdan, Jr

Michael Evans Graham

Marshall Gordon Jones

Paul Leonard Dupree

Douglas Gerard Konitzer

Jason Harris Karp

Mark Kevin Meyer

Victor Petrovich Ostroverkhov

Justin John Gambone, Jr

Gregory Terrence Garay

Todd Jay Rockstroh

Russell Scott Miller

Lang Yuan

Subhrajit Roychowdhury

Howard Roscoe Hart, Jr

Kevin George Harding

John Broddus Deaton, Jr

James William Sears

Brian Scott McCarthy

Harry Kirk Mathews, Jr

Andrew Lee Trimmer

Michael Francis Xavier Gigliotti, Jr

Scott Andrew Weaver

Mark Allen Cheverton

Jinjie Shi

Younkoo Jeong

Christopher James Hayden

Bin Wei

Joshua Tyler Mook

Andrew Philip Woodfield

Steven Jude Duclos

Michael Francis Xavier Gigliotti

Edward James Nieters

Thomas Charles Adcock

John Paul Davis

John Joseph Madelone, Jr

Pinghai Yang

Andrew David Deal

Juan Pablo Cilia

Jared Micheal Iverson

Ning Zhou

David Henry Abbott

Michael John Fornasiero

Paul Mario Marruso

Michael Francis Gigliotti

Bernard Patrick Bewlay

Ronald Scott Bunker

James Anthony Ruud

Wayne Charles Hasz

Lawrence Bernard Kool

Daniel Jason Erno

Apostolos Pavlos Karafillis

Michael F Henry

Yong Yang

Eric Allen Ott

Hsin-Pang Wang

Boris I Medovar

Matthias Hoebel

Clifford Earl Shamblen

Prabhjot Singh

Franz Hugo

Laura Cerully Dial

Peter G Frischmann

Yanzhe Yang

Mark Marshall Meyers

David Toledano

Andrew J Martin

Mohammed Mounir Shalaby

Scott Michael Miller

Zhen Liu

Samuel Vinod Thamboo

Scott Michael Oppenheimer

Michael Charles Ostrowski

Christopher James Kenny

Ming Jia

Jessica Godin Karp

Samar Jyoti Kalita

Rajendra Madhukar Kelkar

Yibo Gao

Justin John Gambone

Lev Borisovich Medovar

Janel Koca Browning

Meisam Salahshoor Pirsoltan

William Monaghan

Christine Mary Furstoss

Smara Jyoti Kalita

Felix Guenter Muller

Victor Petrovish Ostroverkhov

Huiyu Xu

Pawan Sudhindra Rao

Brian Scott Mccarthy

Rajendra Machukar Kelkar

Andrew Lee′ Trimmer

David S Toledano

Jr Gambone Justin John

Justin John Gambore

An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

Additive manufacturing system and method of forming an object in a powder bed

An additive manufacturing (AM) apparatus is provided, having a build unit including a powder delivery mechanism, a powder recoating mechanism, and an irradiation beam directing mechanism. The AM apparatus further includes a rotatable build platform having an inner diameter and an outer diameter. A fluid flow mechanism includes an inlet body forming an inlet plenum and a collector body extended from the inlet body. The collector body forms a collector plenum in fluid communication with the inlet plenum. The collector body forms an outlet opening, wherein the outlet opening is positioned proximate to the inner diameter of the rotatable build platform. The outlet opening is configured to provide a flow of fluid toward the outer diameter above the rotatable build platform.

Additive manufacturing apparatus and fluid flow mechanism

An additive manufacturing system may include a build platform configured to receive a particulate, a particulate dispenser configured to deposit the particulate onto said build platform, a consolidation device configured to consolidate at least a portion of the particulate to form a component, a first actuator assembly configured to rotate said build platform about a rotation axis at a first speed, and a second actuator assembly configured to rotate said shaft about the rotation axis at a second speed different from the first speed.

Additive manufacturing systems and methods including rotating build platform

A system is configured for machining a workpiece (), the workpiece includes an interior surface () that defines an internal passage (). The system includes an electrode () located within the internal passage and electrically isolated from the workpiece, an electrolyte supply, a power supply, and a remover. The electrolyte supply is configured for circulating an electrolyte in a gap between the electrode and the workpiece. The power supply is configured for applying a voltage between the electrode and the workpiece to facilitate smoothing the interior surface. The remover is configured for completely removing the electrode from within the internal passage after smoothing the interior surface.

System and method for machining workpiece and article machined therefrom

A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.

Diode laser fiber array for contour of powder bed fabrication or repair

Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Apparatus and method for direct writing of single crystal super alloys and metals

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

A system and method including receiving a data model representation of a part, the data model representation including at least one layer of the part and inner and outer contours for the at least one layer; determining a hatch pattern for each layer of the at least one layer of the part, the hatch pattern for each layer being dependent on the inner and outer contours for each respective layer; generating a record of the determined hatch pattern for each layer, the record including locations for the hatch pattern for each layer; and saving the record of the determined hatch pattern for each layer of the part. In some aspects, the record of the determined hatch pattern for each layer of the part may be used in an additive manufacturing process.

Method and system of additive manufacturing contour-based hatching

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

An additive manufacturing system is provided. The additive manufacturing system includes a build platform and at least one workstation. The build platform defines a continuous workflow path and is configured to rotate about a build platform axis. The workstation is spaced apart from the build platform along the third direction and at least one of the build platform and the workstation is configured to move along the third direction. The workstation includes at least one particle delivery device, at least one recoating device, and at least one consolidation device. The particle delivery device is configured to deposit particles on the build platform. The recoating device is configured to distribute the deposited particles to form a build layer on the build platform. The consolidation device is configured to consolidate at least a portion of the build layer.

Systems and methods for additive manufacturing

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.

A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

Layered manufacturing of single crystal alloy components

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

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.

Growing community of inventors

Galway, NY, United States of America

William Thomas Carter