Patents by Inventor Darren Beckett
Darren Beckett has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
-
Systems and methods for measuring radiated thermal energy during an additive manufacturing operation
Patent number: 11938560Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.Type: GrantFiled: June 14, 2022Date of Patent: March 26, 2024Assignee: DIVERGENT TECHNOLOGIES, INC.Inventors: R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Darren Beckett, Alberto M. Castro -
Publication number: 20230258575Abstract: An additive manufacturing system comprises an apparatus arranged to distribute layer of metallic powder across a build plane and a power source arranged to emit a beam of energy at the build plane and fuse the metallic powder into a portion of a part. The system includes a processor configured to steer the beam of energy across the build plane and receive data generated by one or more sensors that detect electromagnetic energy emitted from the build plane when the beam of energy fuses the metallic powder. The received data is converted into one or more parameters that indicate one or more conditions at the build plane while the beam of energy fuses the metallic powder. The one or more parameters are used as input into a machine learning algorithm to detect one or more defects in the fused metallic powder.Type: ApplicationFiled: November 17, 2022Publication date: August 17, 2023Applicant: Sigma Labs, Inc.Inventors: Darren Beckett, Roger Frye, Christina Xuan Yu, Scott Betts, Lars Jacquemetton, Kevin C. Anderson
-
Patent number: 11536671Abstract: An additive manufacturing system comprises an apparatus arranged to distribute layer of metallic powder across a build plane and a power source arranged to emit a beam of energy at the build plane and fuse the metallic powder into a portion of a part. The system includes a processor configured to steer the beam of energy across the build plane and receive data generated by one or more sensors that detect electromagnetic energy emitted from the build plane when the beam of energy fuses the metallic powder. The received data is converted into one or more parameters that indicate one or more conditions at the build plane while the beam of energy fuses the metallic powder. The one or more parameters are used as input into a machine learning algorithm to detect one or more defects in the fused metallic powder.Type: GrantFiled: July 30, 2021Date of Patent: December 27, 2022Assignee: SIGMA LABS, INC.Inventors: Darren Beckett, Roger Frye, Christina Xuan Yu, Scott Betts, Lars Jacquemetton, Kevin C. Anderson
-
SYSTEMS AND METHODS FOR MEASURING RADIATED THERMAL ENERGY DURING AN ADDITIVE MANUFACTURING OPERATION
Publication number: 20220388249Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.Type: ApplicationFiled: June 14, 2022Publication date: December 8, 2022Applicant: Sigma Labs, Inc.Inventors: R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Darren Beckett, Alberto M. Castro -
Publication number: 20220382250Abstract: In some aspects, the additive manufacturing system may access, by a processor of an additive manufacturing system, a machine learning model that is trained to identify defects within a build plane. Also, the additive manufacturing system may capture, by an imaging system of the additive manufacturing system, an image of a build plane of the additive manufacturing system. The build plane can contain an object being manufactured through an additive manufacturing process. In addition, the additive manufacturing system may provide, by the processor, the captured image as an input to the machine learning model. Moreover, the additive manufacturing system may receive, by the processor, an output from the machine learning model identifying a defect in the build plane.Type: ApplicationFiled: May 31, 2022Publication date: December 1, 2022Applicant: Sigma Labs, Inc.Inventors: Roger Frye, Christina Xuan Yu, Darren Beckett, Martin S. Piltch, Lars Jacquemetton, Kevin C. Anderson
-
SYSTEMS AND METHODS FOR MEASURING RADIATED THERMAL ENERGY DURING AN ADDITIVE MANUFACTURING OPERATION
Publication number: 20220324056Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.Type: ApplicationFiled: June 22, 2022Publication date: October 13, 2022Applicant: Sigma Labs, Inc.Inventors: Darren Beckett, Scott Betts, Martin Piltch, R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Alberto M. Castro, Roger Frye -
APPARATUS AND METHODS FOR CALIBRATING ON-AXIS TEMPERATURE SENSORS FOR ADDITIVE MANUFACTURING SYSTEMS
Publication number: 20220324026Abstract: This disclosure describes various methods and apparatus for calibration of temperature sensors in additive manufacturing systems. A method for calibration of temperature sensors can include selecting a first wavelength and a second wavelength spaced apart from the first wavelength; measuring an amount of energy radiated from a black body source at the first wavelength; measuring an amount of energy radiated from the black body source at the second wavelength; generating a relationship between a ratio of the amount of energy radiated at the first wavelength to the amount of energy radiated at the second wavelength; and determining, using the relationship, variations in a temperature of a build plane of an additive manufacturing system based upon a ratio of energy radiated at the first wavelength to energy radiated at the second wavelength.Type: ApplicationFiled: April 13, 2022Publication date: October 13, 2022Applicant: Sigma Labs, Inc.Inventors: Darren Beckett, Martin S. Piltch, Lars Jacquemetton, Alberto M. Castro, Brett Diehl -
Systems and methods for measuring radiated thermal energy during an additive manufacturing operation
Patent number: 11390035Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.Type: GrantFiled: September 18, 2019Date of Patent: July 19, 2022Assignee: SIGMA LABS, INC.Inventors: R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Darren Beckett, Alberto M. Castro -
Publication number: 20220111444Abstract: This disclosure describes an additive manufacturing system that includes a build plane having a first region and a second region. Multiple energy source can be positioned above the build plane and configured to direct energy into the first and second regions of the build plane. The system includes optical sensors configured to monitor an intensity of light emitted from the energy sources. A processor associated with the additive manufacturing system is configured to adjust the sensor outputs in response to the energy sources coming into close proximity.Type: ApplicationFiled: December 17, 2021Publication date: April 14, 2022Applicant: Sigma Labs, Inc.Inventors: R. Bruce Madigan, Mark J. Cola, Scott Betts, Darren Beckett, Alberto M. Castro, Lars Jacquemetton, Martin Piltch
-
Patent number: 11260456Abstract: This disclosure describes an additive manufacturing system that includes a build plane having a first region and a second region. Multiple energy source can be positioned above the build plane and configured to direct energy into the first and second regions of the build plane. The system includes optical sensors configured to monitor an intensity of light emitted from the energy sources. A processor associated with the additive manufacturing system is configured to adjust the sensor outputs in response to the energy sources coming into close proximity.Type: GrantFiled: August 26, 2020Date of Patent: March 1, 2022Assignee: SIGMA LABS, INC.Inventors: R. Bruce Madigan, Mark J. Cola, Scott Betts, Darren Beckett, Alberto M. Castro, Lars Jacquemetton, Martin Piltch
-
Publication number: 20220042924Abstract: An additive manufacturing system comprises an apparatus arranged to distribute layer of metallic powder across a build plane and a power source arranged to emit a beam of energy at the build plane and fuse the metallic powder into a portion of a part. The system includes a processor configured to steer the beam of energy across the build plane and receive data generated by one or more sensors that detect electromagnetic energy emitted from the build plane when the beam of energy fuses the metallic powder. The received data is converted into one or more parameters that indicate one or more conditions at the build plane while the beam of energy fuses the metallic powder. The one or more parameters are used as input into a machine learning algorithm to detect one or more defects in the fused metallic powder.Type: ApplicationFiled: July 30, 2021Publication date: February 10, 2022Applicant: Sigma Labs, Inc.Inventors: Darren Beckett, Roger Frye, Christina Xuan Yu, Scott Betts, Lars Jacquemetton, Kevin C. Anderson
-
Publication number: 20210394302Abstract: An additive manufacturing system includes a work region having a layer of metallic powder distributed across at least a portion of the work region. The system further includes a power source, a scanning and focusing system and a processor. The processor is configured to control the power source to emit a beam of energy at a power level and to manipulate the beam of energy across the work region in a plurality of build tracks to form a part from the fused metallic powder. The processor further determines a cooling rate at a termination of each of the plurality of build tracks and controls the power level of the power source in response to the determined cooling rate.Type: ApplicationFiled: June 16, 2021Publication date: December 23, 2021Applicant: SIGMA LABS, INC.Inventors: Lars Jacquemetton, Martin S. Piltch, Darren Beckett
-
Publication number: 20210138578Abstract: An additive manufacturing system comprises a build plane and an energy source configured to direct energy onto a work region of the build plane. An optical detector is configured to receive one or more optical signals from the work region. An optical filter is positioned between the work region and the optical detector, wherein the optical filter includes a first partially transmissive polarized filter having a first polarization axis and a second partially transmissive polarized filter having a second polarization axis. The first polarization axis is rotationally offset from the second polarization axis approximately 90 degrees. The optical filter improves the signal to noise ratio of the optical sensors.Type: ApplicationFiled: November 6, 2020Publication date: May 13, 2021Applicant: SIGMA LABS, INC.Inventors: Darren Beckett, Martin S. Piltch, Scott Betts, Alberto M. Castro, Kevin Anderson, Lars Jacquemetton, Luis Aguilar
-
Publication number: 20210046546Abstract: This disclosure describes an additive manufacturing system that includes a build plane having a first region and a second region. Multiple energy source can be positioned above the build plane and configured to direct energy into the first and second regions of the build plane. The system includes optical sensors configured to monitor an intensity of light emitted from the energy sources. A processor associated with the additive manufacturing system is configured to adjust the sensor outputs in response to the energy sources coming into close proximity.Type: ApplicationFiled: August 26, 2020Publication date: February 18, 2021Applicant: Sigma Labs, Inc.Inventors: R. Bruce Madigan, Mark J. Cola, Scott Betts, Darren Beckett, Alberto M. Castro, Lars Jacquemetton, Martin Piltch
-
Patent number: 10786850Abstract: This disclosure describes an additive manufacturing system that includes a build plane having a first region and a second region. Multiple energy source can be positioned above the build plane and configured to direct energy into the first and second regions of the build plane. The system includes optical sensors configured to monitor an intensity of light emitted from the energy sources. A processor associated with the additive manufacturing system is configured to adjust the sensor outputs in response to the energy sources coming into close proximity.Type: GrantFiled: February 21, 2019Date of Patent: September 29, 2020Assignee: SIGMA LABS, INC.Inventors: R. Bruce Madigan, Mark J. Cola, Scott Betts, Darren Beckett, Alberto M. Castro, Lars Jacquemetton, Martin Piltch
-
SYSTEMS AND METHODS FOR MEASURING RADIATED THERMAL ENERGY DURING AN ADDITIVE MANUFACTURING OPERATION
Publication number: 20200290154Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.Type: ApplicationFiled: March 26, 2020Publication date: September 17, 2020Applicant: Sigma Labs, Inc.Inventors: Darren Beckett, Scott Betts, Martin Piltch, R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Alberto M. Castro, Roger Frye -
Systems and methods for measuring radiated thermal energy during an additive manufacturing operation
Patent number: 10639745Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.Type: GrantFiled: February 21, 2019Date of Patent: May 5, 2020Assignee: SIGMA LABS, INC.Inventors: Darren Beckett, Scott Betts, Martin Piltch, R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Alberto M. Castro, Roger Frye -
SYSTEMS AND METHODS FOR MEASURING RADIATED THERMAL ENERGY DURING AN ADDITIVE MANUFACTURING OPERATION
Publication number: 20200101671Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.Type: ApplicationFiled: September 18, 2019Publication date: April 2, 2020Applicant: Sigma Labs, Inc.Inventors: R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Darren Beckett, Alberto M. Castro -
Systems and methods for measuring radiated thermal energy during an additive manufacturing operation
Patent number: 10479020Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.Type: GrantFiled: August 1, 2018Date of Patent: November 19, 2019Assignee: SIGMA LABS, INC.Inventors: R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Darren Beckett, Alberto M. Castro -
Publication number: 20190255614Abstract: This disclosure describes an additive manufacturing system that includes a build plane having a first region and a second region. Multiple energy source can be positioned above the build plane and configured to direct energy into the first and second regions of the build plane. The system includes optical sensors configured to monitor an intensity of light emitted from the energy sources. A processor associated with the additive manufacturing system is configured to adjust the sensor outputs in response to the energy sources coming into close proximity.Type: ApplicationFiled: February 21, 2019Publication date: August 22, 2019Applicant: Sigma Labs, Inc.Inventors: R. Bruce Madigan, Mark J. Cola, Scott Betts, Darren Beckett, Alberto M. Castro, Lars Jacquemetton, Martin Piltch