Patents by Inventor MacKenzie Ryan Redding
MacKenzie Ryan Redding 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: 20230381864Abstract: An additive manufacturing machine includes an energy beam system configured to emit an energy beam utilized in an additive manufacturing process, and first and second optical elements utilized by, or defining a portion of, the energy beam system and/or an imaging system of the additive manufacturing machine. The imaging system monitors one or more operating parameters of the additive manufacturing process. A light source is configured to emit an assessment beam that follows an optical path incident upon the first and second optical elements. One or more light sensors detect a reflected beam that is either internally reflected by the first optical element or reflectively propagated between the first and second optical elements. A control system determines, based at least in part on assessment data comprising data from the one or more light sensors, whether at least one of the first and second optical elements exhibits an optical anomaly.Type: ApplicationFiled: August 11, 2023Publication date: November 30, 2023Inventors: Fabian Zeulner, Christian Dicken, Justin Mamrak, MacKenzie Ryan Redding, Bertram Gaerber
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Patent number: 11752558Abstract: An additive manufacturing machine may include an energy beam system configured to emit an energy beam utilized in an additive manufacturing process, and one or more optical elements utilized by, or defining a portion of, the energy beam system and/or an imaging system of the additive manufacturing machine. The imaging system may be configured to monitor one or more operating parameters of the additive manufacturing process. The additive manufacturing machine may include a light source configured to emit an assessment beam that follows an optical path incident upon the one or more optical elements, and one or more light sensors configured to detect a reflected beam comprising at least a portion of the assessment beam reflected and/or transmitted by at least one of the one or more optical elements.Type: GrantFiled: April 16, 2021Date of Patent: September 12, 2023Assignees: General Electric Company, Concept Laser GmbHInventors: Fabian Zeulner, Christian Dicken, Justin Mamrak, MacKenzie Ryan Redding, Bertram Gaerber
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Patent number: 11745426Abstract: A method, apparatus, and program for additive manufacturing. The additive manufacturing method may include solidifying at least a portion of a first layer (601) of build material (416) within a first scan region (902A). At least one of a build unit (400) and a build platform (310) may be moved to solidify at least a portion of the first layer (601) of build material (416) within a second scan region (902B). A second layer (602) of build material (416) may be provided over at least a portion of the first scan region (902A) and the second scan region (902B). A second layer (602) of build material (416) may be solidified within at least a portion of the third scan region (902C), the third scan region (902C) may at least partially overlap and may be offset with relation to the first scan region (902A).Type: GrantFiled: November 2, 2018Date of Patent: September 5, 2023Assignee: General Electric CompanyInventors: Justin Mamrak, MacKenzie Ryan Redding, Thomas Graham Spears
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Patent number: 11667095Abstract: 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.Type: GrantFiled: May 20, 2022Date of Patent: June 6, 2023Assignee: General Electric CompanyInventors: Michelle Lynn Sloderbeck, Christopher Hall, Laura Banks, Tim Murphy, David Ploetz, Zachary Fieldman, Christopher C. Chapman, Emily Bautista, MacKenzie Ryan Redding
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Patent number: 11612937Abstract: An additive manufacturing machine (910) includes a build platform (908) extending within a horizontal plane (H) and a gantry (930) positioned above the build platform (908) and defining a build area (932). A build unit (920) includes a powder dispenser (906) for discharging a layer of additive powder (902) and an energy source (922) for selectively directing energy toward the layer of additive powder (902) to fuse portions of the layer of additive powder (902). The gantry (930) movably supports the build unit (920) within the build area and a powder supply system (900) is positioned below the gantry (930) and extends between a powder supply source (940) and the powder dispenser (906).Type: GrantFiled: November 2, 2018Date of Patent: March 28, 2023Assignee: General Electric CompanyInventors: MacKenzie Ryan Redding, Frank Schodel
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Patent number: 11584073Abstract: An additive manufacturing machine (900) includes a build unit (904) that is supported by an overhead gantry (918). The build unit (904) includes a powder dispenser (906) including a vibration mechanism (922) and a scan unit (908) including a powder fusing device (910) for fusing or binding portions of a layer of additive powder. A vibration isolation device (932), such as a passive rubber damper (940) or an active vibration canceling mechanism (960), is positioned between the powder dispenser (906) and the scan unit (908) to prevent vibrations in the powder dispenser (906) from causing operational issues with the scan unit (908) and inaccuracies in the additive manufacturing process.Type: GrantFiled: November 2, 2018Date of Patent: February 21, 2023Assignee: General Electric CompanyInventors: Justin Mamrak, MacKenzie Ryan Redding
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Patent number: 11524451Abstract: An additive manufacturing apparatus is provided. The additive manufacturing apparatus may include a stabilizing system; a build platform on the stabilizing system; and a build unit positioned over the build platform, wherein the build unit comprises a powder dispenser and a recoater blade. Methods are also provided for making an object from powder.Type: GrantFiled: November 2, 2018Date of Patent: December 13, 2022Assignee: General Electric CompanyInventors: Justin Mamrak, MacKenzie Ryan Redding
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Patent number: 11478853Abstract: A method of monitoring an additive manufacturing process in which one or more energy beams are used to selectively fuse a powder to form a workpiece, in the presence of one or more plumes generated by interaction of the one or more energy beams with the powder. The method includes using at least one sensor to generate at least one signal representative of a trajectory of one or more of the plumes.Type: GrantFiled: December 23, 2016Date of Patent: October 25, 2022Assignee: General Electric CompanyInventors: Andrew J. Martin, Mackenzie Ryan Redding, Justin Mamrak
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Publication number: 20220331876Abstract: An additive manufacturing machine may include an energy beam system configured to emit an energy beam utilized in an additive manufacturing process, and one or more optical elements utilized by, or defining a portion of, the energy beam system and/or an imaging system of the additive manufacturing machine. The imaging system may be configured to monitor one or more operating parameters of the additive manufacturing process. The additive manufacturing machine may include a light source configured to emit an assessment beam that follows an optical path incident upon the one or more optical elements, and one or more light sensors configured to detect a reflected beam comprising at least a portion of the assessment beam reflected and/or transmitted by at least one of the one or more optical elements.Type: ApplicationFiled: April 16, 2021Publication date: October 20, 2022Inventors: Fabian Zeulner, Christian Dicken, Justin Mamrak, MacKenzie Ryan Redding, Bertram Gaerber
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Publication number: 20220274166Abstract: 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.Type: ApplicationFiled: May 20, 2022Publication date: September 1, 2022Inventors: Michelle Lynn Sloderbeck, Christopher Hall, Laura Banks, Tim Murphy, David Ploetz, Zachary Fieldman, Christopher C. Chapman, Emily Bautista, MacKenzie Ryan Redding
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Patent number: 11396135Abstract: An additive manufacturing machine (910) includes a build unit (920) comprising a powder dispenser (906) including a hopper (1004) for receiving a volume of additive powder (1006). A powder supply system (1000) includes a powder supply source (1010) for providing additive powder (1006) into the hopper (1004) during a refill process. A powder reclamation system (1002) includes a vacuum pump (1030) coupled to a vacuum duct (1034, 1036) defining a suction inlet (1040) positioned for collecting misdirected additive powder (1006) dispensed during the refill process. A return duct (1038) includes a filter mechanism (1050) may filter and return the collected additive powder (1006) back to the powder supply source (1010) for reuse.Type: GrantFiled: November 6, 2018Date of Patent: July 26, 2022Assignee: General Electric CompanyInventors: Justin Mamrak, MacKenzie Ryan Redding, Jordan Maxine Shoemaker, Michael Thomas Gansler
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Patent number: 11370031Abstract: 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.Type: GrantFiled: October 16, 2020Date of Patent: June 28, 2022Assignee: General Electric CompanyInventors: MacKenzie Ryan Redding, Zachary David Fieldman, Justin Mamrak
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Patent number: 11364564Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.Type: GrantFiled: November 13, 2017Date of Patent: June 21, 2022Assignee: General Electric CompanyInventors: Justin Mamrak, MacKenzie Ryan Redding, Mark Kevin Meyer
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Patent number: 11351605Abstract: 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.Type: GrantFiled: May 18, 2017Date of Patent: June 7, 2022Assignee: General Electric CompanyInventors: Michelle Lynn Sloderbeck, Christopher Hall, Laura Banks, Tim Murphy, David Ploetz, Zachary Fieldman, Christopher C. Chapman, Emily Bautista, MacKenzie Ryan Redding
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Patent number: 11318535Abstract: A method is provided for controlling an additive manufacturing process in which one or more energy beams are used to selectively fuse a powder contained in an additive manufacturing machine having a gas flow therein in order to form a workpiece, in the presence of one or more plumes generated by interaction of the one or more energy beams with the powder, wherein the process is controlled by an electronic controller. The method includes: performing a build process to form a workpiece using a set of initial process parameters; sensing a condition of the finished workpiece; using the electronic controller, comparing the condition of the finished workpiece to a predetermined standard; using the electronic controller, changing one or more of the initial process parameters to define a set of revised process parameters; and performing a subsequent build process using the revised process parameters.Type: GrantFiled: December 23, 2016Date of Patent: May 3, 2022Assignee: General Electric CompanyInventors: Justin Mamrak, Andrew J. Martin, Mackenzie Ryan Redding
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Publication number: 20220111599Abstract: A method of operating an additive manufacturing machine may include determining an operational state and/or a remedial event for the machine based on optical anomalies on one or more optical elements of an energy beam system determined by image data from a light sensor that detects a reflected portion of an imaging beam reflected by the optical elements. The remedial event may include a maintenance event and/or a replacement event. An object may be additively manufactured using nominal operating conditions during a nominal operational state, and/or using one or more augmented operating conditions during an augmented operational state. A maintenance operation may be performed, such as cleaning and/or calibrating the one or more optical elements and/or one or more components of the energy beam system, upon having determined the remedial event that comprises the maintenance event.Type: ApplicationFiled: October 14, 2020Publication date: April 14, 2022Inventors: Justin Mamrak, MacKenzie Ryan Redding, Bertram Gaerber
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Patent number: 11253922Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.Type: GrantFiled: May 31, 2017Date of Patent: February 22, 2022Assignee: General Electric CompanyInventors: Brandon Holford, Jeffrey Vaught, MacKenzie Ryan Redding, Justin Mamrak
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Publication number: 20210370394Abstract: Additive manufacturing apparatus, along with methods of forming an object therewith, are provided. The additive manufacturing apparatus may include at least one build unit; a build platform (such as a rotating build platform); and a pair of collectors positioned on the apparatus such that a first collector contacts an outer surface of an object as it is formed on the build platform and a second collector contacts an inner surface of the object as it is formed on the build platform.Type: ApplicationFiled: November 2, 2018Publication date: December 2, 2021Inventors: MacKenzie Ryan Redding, Andrew David Simpson, Justin Mamrak
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Patent number: 11141918Abstract: An additive manufacturing machine (910) includes a build unit (920) including a powder dispenser (906) having a hopper (904) for receiving a volume of additive powder (902). A powder supply system (1000) includes a powder supply source (940) and a conveyor (1024) for transporting dispensed additive powder (902) to the hopper (904). A supply sensing system (1060) monitors the additive powder (902) that is dispensed from the powder supply source (940) and transported to the hopper (904) and a hopper sensing system (1040) monitors the additive powder (902) within the hopper (904). Each of these systems includes one or more powder level sensors (1042, 1044, 1062), weight sensors (1050, 1064), and/or vision systems (1054, 1070) for monitoring the additive powder (902).Type: GrantFiled: November 2, 2018Date of Patent: October 12, 2021Assignee: General Electric CompanyInventors: Justin Mamrak, MacKenzie Ryan Redding
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Publication number: 20210283692Abstract: 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.Type: ApplicationFiled: December 7, 2017Publication date: September 16, 2021Inventors: MacKenzie Ryan Redding, Justin Mamrak, Zachary David Fieldman