General Electric Company

Zachary David Fieldman

MacKenzie Ryan Redding

Justin Mamrak

Daniel Joerger

Neal Dunham

Todd Jay Rockstroh

Theodore Anderson

Thomas Sinnett

Christopher C Chapman

Christopher Hall

Emily Bautista

Laura Banks

Tim Murphy

Michelle Lynn Sloderbeck

David Ploetz

Scott Alan Gold

Mike D Miller

Eliezer Manuel Alcantara Marte

Michelle Lynn Habib

The present disclosure relates to systems, methods, and apparatuses () for monitoring the flow of a powder (). A powder distribution system () may include an inlet () for receiving powder () from a powder reservoir (). The powder reservoir () may include an outlet () to supply powder () received from the inlet (). The apparatus () may further include a powder flow sensor () configured to monitor a quantity of powder supplied by the outlet (), and wherein the quantity of powder supplied by the outlet () is controlled, at least in part by a monitored output of the powder flow sensor ().

Closed loop gated recoater monitoring system

The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the 'gas plume') without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

Additive manufacturing using a dynamically grown build envelope

The present disclosure generally relates to additive manufacturing systems and methods involving a mechanism for feeding in a desired amount of fresh recoater blade. This can be accomplished by, for example, spooling the fresh blade material from a spool. This helps prevent work stoppage when a portion of a recoater blade becomes damaged. As such, the present disclosure also relates to a system and method for detecting whether a recoater blade is damaged, and if there is damage, then causing a fresh blade portion to be fed in.

Apparatuses for continuously refreshing a recoater blade for additive manufacturing including a blade feed unit and arm portion

The present disclosure generally relates to powder packing for additive manufacturing (AM) methods and systems. Conventional powder packing methods are manual and non-standardized, and they result in operator fatigue and potentially product inconsistencies. Powder packing according to the present disclosure improves standardization and reduces turnaround time, with the potential to lower the cost of AM.

Powder packing methods and apparatus

Large scale additive machine

Method and apparatus for continuously refreshing a recoater blade for additive manufacturing

The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support structure in the process of building objects that may be removed by rotating the support structure to a second orientation before removal, as well as novel support structures to be used within these AM processes. The support structures are fabricated in a first orientation and then rotated to the second orientation. The support structures are removed by passing through an outlet of the object.

Methods and keyway supports for additive manufacturing

The present disclosure generally relates to methods for additive manufacturing (AM) that utilize breakable structures in the process of building objects, as well as novel breakable support structures to be used within these AM processes. A support structure includes a weakened portion and the object includes an outlet. The method includes breaking the removable support structure at the weakened portion into at least two parts.

Methods and breakable supports for additive manufacturing

Additive manufacturing using a mobile build volume

Additive manufacturing using a selective recoater

A method, apparatus, and program for calibrating an additive manufacturing apparatus. In one aspect, a method is disclosed for calibrating an additive manufacturing apparatus. The method includes forming a first solidified portion within a first scan region, wherein the solidified portion within the first scan region is formed by irradiating a build material while a build unit is in a first location. The method further includes forming a second solidified portion within a second scan region, wherein the second solidified portion within the second scan region is formed by irradiating a build material while a build unit is in a second location different from said first location. An alignment of the additive manufacturing apparatus determined based on the detected alignment of the first solidified portion and the second solidified portion.

Interlace calibration and methods of use thereof

Additive manufacturing using a mobile scan area

Growing community of inventors

Hamilton, OH, United States of America

Zachary David Fieldman