Patents by Inventor Dean Andrew Snelling
Dean Andrew Snelling 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).
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Publication number: 20230278282Abstract: 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.Type: ApplicationFiled: May 15, 2023Publication date: September 7, 2023Inventors: Brian Scott McCarthy, Dean Andrew Snelling, JR., Thomas Adcock, Donnell Crear, Michael Evans Graham
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Patent number: 11679551Abstract: 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.Type: GrantFiled: February 28, 2019Date of Patent: June 20, 2023Assignee: General Electric CompanyInventors: Brian Scott McCarthy, Dean Andrew Snelling, Jr., Thomas Adcock, Donnell Crear, Michael Evans Graham
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Patent number: 10974474Abstract: An applicator repair system for an additive manufacturing (AM) system, and an AM system including the same are disclosed. The applicator repair system includes a repair device including a repair element configured to repair a damaged applicator element on an applicator of an AM system. The damaged applicator element is configured to distribute a layer of raw material on a build platform of the AM system. The repair device is positioned within a processing chamber of the AM system. A damaged applicator controller may be provided that is configured to cause repair of the damaged active applicator in response to the damaged applicator being identified as damaged.Type: GrantFiled: June 12, 2017Date of Patent: April 13, 2021Assignee: General Electric CompanyInventors: Donnell Eugene Crear, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling
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Publication number: 20200276764Abstract: 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.Type: ApplicationFiled: February 28, 2019Publication date: September 3, 2020Inventors: Brian Scott MCCARTHY, Dean Andrew SNELLING, JR., Thomas ADCOCK, Donnell CREAR, Michael Evans GRAHAM
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Patent number: 10688593Abstract: A component includes a body, and an interface in the body defining a first and second portion of the body made by different melting beam sources of a multiple melting beam source additive manufacturing system during a single build. The component also includes a channel extending through the body. The channel includes an interface-distant area on opposing sides of the interface, each interface-distant area having a first width. The channel also includes an enlarged width area fluidly communicative with the interface-distant areas and spanning the interface, the enlarged width area having a second width larger than the first width. Any misalignment of the melting beams at the interface is addressed by the enlarged width area, eliminating the problem of reduced cooling fluid flow in the channel.Type: GrantFiled: June 19, 2017Date of Patent: June 23, 2020Assignee: General Electric CompanyInventors: Felix Martin Gerhard Roerig, Donnell Eugene Crear, Juan Vicente Haro Gonzalez, Mikhail Pavlov, Dean Andrew Snelling, Jr.
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Patent number: 10596803Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a build plate positioned directly on a movable build platform, and a recoater device positioned above the build plate. The recoater device may include a blade. Additionally, the AMS may include a calibration system operably connected to the recoater device. The calibration system may include at least one measurement device coupled or positioned adjacent to the recoater device, and at least one computing device operably connected to the measurement device(s). The computing device(s) may be configured to calibrate the recoater device by adjusting a height of the blade of the recoater device relative to a reference surface of a component of the AMS in response to determining a pre-build distance between the blade of the recoater device and the reference surface differs from a desired distance. The pre-build distance may be determined using the measurement device(s).Type: GrantFiled: May 30, 2017Date of Patent: March 24, 2020Assignee: General Electric CompanyInventors: Donnell Eugene Crear, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling, Jr.
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Patent number: 10596802Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a movable build platform, and a calibration system operably connected to the build platform. The calibration system may include a reflective element operably coupled to the build platform, a first calibration model positioned above and vertically offset from the reflective element, and a first camera substantially aligned with the first calibration model. The first camera may be visually aligned with the reflective element to capture a first reflective image of the first calibration model as reflected by the reflective element. The calibration system may also include at least one computing device operably connected to the build platform and the first camera, and configured to calibrate the build platform by: adjusting an actual inclination of the build platform in response to determining the first reflective image differs from a predetermined image of the first calibration model.Type: GrantFiled: May 30, 2017Date of Patent: March 24, 2020Assignee: General Electric CompanyInventors: Mikhail Pavlov, Donnell Eugene Crear, Felix Martin Gerhard Roerig, Dean Andrew Snelling, Jr.
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Patent number: 10379063Abstract: A damaged applicator identifier system for an additive manufacturing (AM) system, and AM system including the same are disclosed. The damaged applicator identifier system may include a damaged applicator identifier determining whether the active applicator is damaged by identifying a non-planar surface in a layer of raw material on a build platform of the AM system after formation of the layer by the active applicator. A damaged applicator controller is configured to cause replacement or repair of the damaged, active applicator in response to the damaged applicator identifier identifying the damaged, active applicator.Type: GrantFiled: June 12, 2017Date of Patent: August 13, 2019Assignee: General Electric CompanyInventors: Donnell Eugene Crear, Tiffany Muller Craft, Kassy Moy Hart, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling
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Publication number: 20180361502Abstract: A component includes a body, and an interface in the body defining a first and second portion of the body made by different melting beam sources of a multiple melting beam source additive manufacturing system during a single build. The component also includes a channel extending through the body. The channel includes an interface-distant area on opposing sides of the interface, each interface-distant area having a first width. The channel also includes an enlarged width area fluidly communicative with the interface-distant areas and spanning the interface, the enlarged width area having a second width larger than the first width. Any misalignment of the melting beams at the interface is addressed by the enlarged width area, eliminating the problem of reduced cooling fluid flow in the channel.Type: ApplicationFiled: June 19, 2017Publication date: December 20, 2018Inventors: Felix Martin Gerhard Roerig, Donnell Eugene Crear, Juan Vicente Haro Gonzalez, Mikhail Pavlov, Dean Andrew Snelling, JR.
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Publication number: 20180356350Abstract: A damaged applicator identifier system for an additive manufacturing (AM) system, and AM system including the same are disclosed. The damaged applicator identifier system may include a damaged applicator identifier determining whether the active applicator is damaged by identifying a non-planar surface in a layer of raw material on a build platform of the AM system after formation of the layer by the active applicator. A damaged applicator controller is configured to cause replacement or repair of the damaged, active applicator in response to the damaged applicator identifier identifying the damaged, active applicator.Type: ApplicationFiled: June 12, 2017Publication date: December 13, 2018Inventors: Donnell Eugene Crear, Tiffany Muller Craft, Kassy Moy Hart, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling
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Publication number: 20180354208Abstract: An applicator repair system for an additive manufacturing (AM) system, and an AM system including the same are disclosed. The applicator repair system includes a repair device including a repair element configured to repair a damaged applicator element on an applicator of an AM system. The damaged applicator element is configured to distribute a layer of raw material on a build platform of the AM system. The repair device is positioned within a processing chamber of the AM system. A damaged applicator controller may be provided that is configured to cause repair of the damaged active applicator in response to the damaged applicator being identified as damaged.Type: ApplicationFiled: June 12, 2017Publication date: December 13, 2018Inventors: Donnell Eugene Crear, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling
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Publication number: 20180347969Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a build platform, and energy emitting device(s) positioned above the build platform. Energy emitting device(s) may be configured to form a test mark directly on a reference surface of the AMS. AMS may also include a calibration system operably connected to the energy emitting device(s). The calibration system may include measurement device(s) configured to determine an actual location of the test mark on the reference surface, and computing device(s) operably connected to the energy emitting device(s) and the measurement device(s). The computing device(s) may be configured to calibrate the energy emitting device(s) by adjusting the energy emitting device(s) in response to determining the actual location of the test mark on the reference surface from a predetermined, desired location on the reference surface.Type: ApplicationFiled: May 30, 2017Publication date: December 6, 2018Inventors: Dean Andrew Snelling, JR., Donnell Eugene Crear, Mikhail Pavlov, Felix Martin Gerhard Roerig
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Publication number: 20180348492Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a movable build platform, and a calibration system operably connected to the build platform. The calibration system may include a reflective element operably coupled to the build platform, a first calibration model positioned above and vertically offset from the reflective element, and a first camera substantially aligned with the first calibration model. The first camera may be visually aligned with the reflective element to capture a first reflective image of the first calibration model as reflected by the reflective element. The calibration system may also include at least one computing device operably connected to the build platform and the first camera, and configured to calibrate the build platform by: adjusting an actual inclination of the build platform in response to determining the first reflective image differs from a predetermined image of the first calibration model.Type: ApplicationFiled: May 30, 2017Publication date: December 6, 2018Inventors: Mikhail Pavlov, Donnell Eugene Crear, Felix Martin Gerhard Roerig, Dean Andrew Snelling, JR.
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Publication number: 20180348367Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a build plate positioned directly on a movable build platform, and a recoater device positioned above the build plate. The recoater device may include a blade. Additionally, the AMS may include a calibration system operably connected to the recoater device. The calibration system may include at least one measurement device coupled or positioned adjacent to the recoater device, and at least one computing device operably connected to the measurement device(s). The computing device(s) may be configured to calibrate the recoater device by adjusting a height of the blade of the recoater device relative to a reference surface of a component of the AMS in response to determining a pre-build distance between the blade of the recoater device and the reference surface differs from a desired distance. The pre-build distance may be determined using the measurement device(s).Type: ApplicationFiled: May 30, 2017Publication date: December 6, 2018Inventors: Donnell Eugene Crear, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling, JR.