Patents by Inventor Christopher David Barnhill
Christopher David Barnhill 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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Patent number: 11958250Abstract: An additive manufacturing apparatus can include a stage configured to hold one or more cured layers of resin that form a component. A radiant energy device can be operable to generate and project radiant energy in a patterned image. An actuator can be configured to change a relative position of the stage relative to the radiant energy device. A reclamation system can be downstream of the stage and can be configured to remove at least a portion of the resin from a resin support. The reclamation system can include a first collection structure configured to accept a resin support therethrough along a resin support movement direction. A first scraper is positioned within the first collection structure. The first scraper has an elongation axis that is offset from the resin support movement direction by an offset angle that is less than 90 degrees.Type: GrantFiled: June 10, 2022Date of Patent: April 16, 2024Assignee: General Electric CompanyInventors: Meredith Elissa Dubelman, Christopher David Barnhill, Xi Yang, William Joseph Steele, Brian Thomas Thompson
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Patent number: 11958249Abstract: A reclamation system for an additive manufacturing apparatus can include a collection structure configured to remove at least a portion of the resin from a foil. A containment vessel can be configured to retain the resin removed from the foil. A drain can direct the resin from the containment vessel to a reservoir.Type: GrantFiled: June 10, 2022Date of Patent: April 16, 2024Assignee: General Electric CompanyInventors: Trent William Muhlenkamp, Christopher David Barnhill, Meredith Elissa Dubelman, Carlos H. Bonilla, Brian Thomas Thompson, John Thomas Sterle
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Patent number: 11951679Abstract: An additive manufacturing apparatus can include a stage configured to hold a component formed by one or more layers of resin. A support plate can be positioned above the stage. A radiant energy device can be positioned above the stage. The radiant energy device can be operable to generate and project energy in a predetermined pattern. A feed module can be configured to operably couple with a first end portion of a resin support and can be positioned upstream of the stage. A take-up module can be configured to operably couple with a second end portion of the resin support and can be positioned downstream of the stage.Type: GrantFiled: June 10, 2022Date of Patent: April 9, 2024Assignee: General Electric CompanyInventors: Mary Kathryn Thompson, Xi Yang, Meredith Elissa Dubelman, William Joseph Steele, Trent William Muhlenkamp, John Thomas Sterle, Christopher David Barnhill
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Publication number: 20240109250Abstract: An additive manufacturing apparatus includes a support configured to support a resin and a constituent material. A support plate includes a window. A stage is configured to hold one or more composite layers of the resin and the constituent material to form a composite component positioned opposite the support plate. A radiant energy device is positioned on an opposite side of the support from the stage and is operable to generate and project radiant energy in a patterned image through the window. An actuator assembly is configured to move the stage in a Z-axis direction and a Y-axis direction.Type: ApplicationFiled: December 14, 2022Publication date: April 4, 2024Inventors: Xi Yang, Christopher David Barnhill, Trent William Muhlenkamp, Joseph Edward Hampshire
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Publication number: 20240100774Abstract: An additive manufacturing apparatus includes a feed module and a take-up module that are configured to operably couple with a foil. A stage is configured to hold one or more cured layers of a resin that form a component. A radiant energy device is positioned opposite to the at least one stage. The radiant energy device is operable to generate and project radiant energy in a predetermined pattern. An actuator is configured to change a relative position of the at least one stage and the foil. An accumulator is positioned between the feed module and the take-up module. The accumulator is configured to retain an intermediate portion of the foil to allow a first portion of the foil upstream of the accumulator to move at a first speed and a second portion of the foil downstream of the accumulator to move at a second speed during a defined time period.Type: ApplicationFiled: November 30, 2023Publication date: March 28, 2024Inventors: Mary Kathryn Thompson, Meredith Elissa Dubelman, Christopher David Barnhill, Xi Yang, Trent William Muhlenkamp, William Joseph Steele
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Publication number: 20240059008Abstract: An additive manufacturing apparatus includes a stage configured to hold a component. A radiant energy device is operable to generate and project radiant energy in a patterned image. An actuator is configured to change a relative position of the stage relative to the radiant energy device. A resin management system includes a material deposition assembly upstream configured to deposit a resin on a resin support. The material deposition assembly includes a reservoir configured to retain a first volume of the resin and define a thickness of the resin on the resin support as the resin support is translated in an X-axis direction. The material deposition assembly further includes a vessel positioned above the reservoir in a Z-axis direction and configured to store a second volume of the resin. In addition, the material deposition assembly includes a conduit configured to direct the resin from the vessel to the reservoir.Type: ApplicationFiled: October 30, 2023Publication date: February 22, 2024Inventors: Meredith Elissa Dubelman, Trent William Muhlenkamp, Kevin Robert Dickson, Christopher David Barnhill, Brian Thomas Thompson
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Publication number: 20240042701Abstract: An additive manufacturing apparatus includes a first print module includes a first stage configured to hold a first component and a first radiant energy device. The resin support is configured to be positioned between the first stage and the first radiant energy device. A second print module includes a second stage configured to hold a second component and a second radiant energy device. The resin support is configured to be positioned between the second stage and the second radiant energy device. A control system is configured to translate the resin support based on a condition of the first print module and the second print module through the first print module and the second print module.Type: ApplicationFiled: October 11, 2023Publication date: February 8, 2024Inventors: Christopher David Barnhill, Robert Edgar Estes, William Joseph Steele, Trent William Muhlenkamp, Zhen Liu, John Thomas Sterle, Victor Wayne Fulton
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Publication number: 20240033993Abstract: An additive manufacturing apparatus is provided herein that includes a resin support configured to support a resin. A support plate includes a window. A stage is configured to hold one or more cured layers of the resin to form a component. Each cured layer is formed with the stage in a respective cure position. A radiant energy device is positioned on an opposite side of the resin support from the stage and is operable to generate and project radiant energy in a patterned image through the window. An actuator is operably coupled with the stage and is configured to move the stage in a Z-axis direction to place the stage in a removal position. The component contacts one of the resin support or the resin supported by the resin support in the removal position.Type: ApplicationFiled: June 28, 2023Publication date: February 1, 2024Inventors: Xi Yang, Meredith Elissa Dubelman, Christopher David Barnhill, William Joseph Steele, Mary Kathryn Thompson
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Publication number: 20240033992Abstract: An additive manufacturing apparatus includes a support plate including a window. A stage is configured to hold one or more cured layers of the resin to form a component. A radiant energy device positioned on an opposite side of the support plate from the stage and operable to generate and project radiant energy in a patterned image through the window. An actuator is operably coupled with the stage and is configured to move the stage between a curing position and a removal position. The curing position can be offset from the removal position.Type: ApplicationFiled: June 28, 2023Publication date: February 1, 2024Inventors: Xi Yang, Meredith Elissa Dubelman, Christopher David Barnhill, William Joseph Steele, Mary Kathryn Thompson
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Patent number: 11865780Abstract: An additive manufacturing apparatus includes a feed module and a take-up module that are configured to operably couple with a foil. A stage is configured to hold one or more cured layers of a resin that form a component. A radiant energy device is positioned opposite to the at least one stage. The radiant energy device is operable to generate and project radiant energy in a predetermined pattern. An actuator is configured to change a relative position of the at least one stage and the foil. An accumulator is positioned between the feed module and the take-up module. The accumulator is configured to retain an intermediate portion of the foil to allow a first portion of the foil upstream of the accumulator to move at a first speed and a second portion of the foil downstream of the accumulator to move at a second speed during a defined time period.Type: GrantFiled: February 26, 2021Date of Patent: January 9, 2024Assignee: General Electric CompanyInventors: Mary Kathryn Thompson, Meredith Elissa Dubelman, Christopher David Barnhill, Xi Yang, Trent William Muhlenkamp, William Joseph Steele
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Patent number: 11826950Abstract: An additive manufacturing apparatus includes a stage configured to hold a component. A radiant energy device is operable to generate and project radiant energy in a patterned image. An actuator is configured to change a relative position of the stage relative to the radiant energy device. A resin management system includes a material deposition assembly upstream configured to deposit a resin on a resin support. The material deposition assembly includes a reservoir configured to retain a first volume of the resin and define a thickness of the resin on the resin support as the resin support is translated in an X-axis direction. The material deposition assembly further includes a vessel positioned above the reservoir in a Z-axis direction and configured to store a second volume of the resin. In addition, the material deposition assembly includes a conduit configured to direct the resin from the vessel to the reservoir.Type: GrantFiled: July 9, 2021Date of Patent: November 28, 2023Assignees: General Electric Company, Unison Industries, LLCInventors: Meredith Elissa Dubelman, Trent William Muhlenkamp, Kevin Robert Dickson, Christopher David Barnhill, Brian Thomas Thompson
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Patent number: 11813799Abstract: An additive manufacturing apparatus includes a first print module includes a first stage configured to hold a first component and a first radiant energy device. The resin support is configured to be positioned between the first stage and the first radiant energy device. A second print module includes a second stage configured to hold a second component and a second radiant energy device. The resin support is configured to be positioned between the second stage and the second radiant energy device. A control system is configured to translate the resin support based on a condition of the first print module and the second print module through the first print module and the second print module.Type: GrantFiled: August 9, 2022Date of Patent: November 14, 2023Assignee: General Electric CompanyInventors: Christopher David Barnhill, Robert Edgar Estes, William Joseph Steele, Trent William Muhlenkamp, Zhen Liu, John Thomas Sterle, Victor Wayne Fulton
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Publication number: 20230330924Abstract: An additive manufacturing apparatus includes a support plate and a foil supporting an uncured layer of a resin. A stage is configured to hold a component of one or more cured layers of the resin. One or more actuators is operable to move the stage away from the support plate in a Z-axis direction. A radiant energy device is positioned opposite the stage such that the support plate is positioned between the radiant energy device and the stage. A foil interaction device includes a first pneumatic actuation zone and a second pneumatic actuation zone. Each of the first and second pneumatic actuation zones is configured to apply a force on a surface of the foil. The first and second pneumatic actuation zones are fluidly separable and configured to apply varied pressures relative to one another to the surface of the foil.Type: ApplicationFiled: June 26, 2023Publication date: October 19, 2023Inventors: Meredith Elissa Dubelman, Christopher David Barnhill, Xi Yang, Lawrence William Nurre, Trent William Muhlenkamp, Mary Kathryn Thompson
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Publication number: 20230302728Abstract: An additive manufacturing apparatus includes a resin support configured to support a first resin and a second resin. A support plate includes a window. A stage is configured to hold one or more cured layers of the resin to form a component positioned opposite the support plate. A radiant energy device is positioned on an opposite side of the resin support from the stage and is operable to generate and project radiant energy in a patterned image through the window. An actuator assembly is configured to move the stage in a Z-axis direction and in a Y-axis direction.Type: ApplicationFiled: March 16, 2023Publication date: September 28, 2023Inventors: Xi Yang, William Joseph Steele, Christopher David Barnhill, Meredith Elissa Dubelman, Trent William Muhlenkamp, Mary Kathryn Thompson
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Patent number: 11731367Abstract: An additive manufacturing apparatus includes a stage configured to hold a component. A radiant energy device is operable to generate and project radiant energy toward the stage. An actuator is configured to change a relative position of the stage relative to the radiant energy device. A feed module is configured to support a feed roll of a resin support upstream of the stage about a feed mandrel. A first control device is operably coupled with the feed mandrel. A take-up module is configured to support a take-up roll of the resin support downstream of the stage about a take-up mandrel. A second control device is operably coupled with the take-up mandrel. A computing system is operably coupled with one or more sensors. The computing system is configured to provide commands to at least one of the first control device or the second control device to respectively rotate the first control device or the second control device to obtain a target tension on the resin support.Type: GrantFiled: June 23, 2021Date of Patent: August 22, 2023Assignee: General Electric CompanyInventors: Zhen Liu, Trent William Muhlenkamp, Christopher David Barnhill
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Patent number: 11707883Abstract: An additive manufacturing apparatus includes a support plate and a foil supporting an uncured layer of a resin. A stage is configured to hold a component of one or more cured layers of the resin. One or more actuators is operable to move the stage away from the support plate in a Z-axis direction. A radiant energy device is positioned opposite the stage such that the support plate is positioned between the radiant energy device and the stage. A foil interaction device includes a first pneumatic actuation zone and a second pneumatic actuation zone. Each of the first and second pneumatic actuation zones is configured to apply a force on a surface of the foil. The first and second pneumatic actuation zones are fluidly separable and configured to apply varied pressures relative to one another to the surface of the foil.Type: GrantFiled: November 20, 2020Date of Patent: July 25, 2023Assignee: General Electric CompanyInventors: Meredith Elissa Dubelman, Christopher David Barnhill, Xi Yang, Lawrence William Nurre, Trent William Muhlenkamp, Mary Kathryn Thompson
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Publication number: 20230067394Abstract: An additive manufacturing apparatus includes a build module. A feed module is configured to support a first portion of a resin support. The first portion of the resin support is supported by a feed mounting panel. A take-up module is configured to support a second portion of the resin support. The second portion of the resin support is supported by a take-up mounting panel and is positioned on an opposing side of the radiant energy device from the feed module. An adjustment assembly is configured to adjust a position of at least one of a feed mandrel within the feed module or a take-up mandrel within the take-up module.Type: ApplicationFiled: August 24, 2021Publication date: March 2, 2023Inventors: Christopher David Barnhill, Zhen Liu, Trent William Muhlenkamp
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Publication number: 20230064479Abstract: An additive manufacturing apparatus includes a first print module includes a first stage configured to hold a first component and a first radiant energy device. The resin support is configured to be positioned between the first stage and the first radiant energy device. A second print module includes a second stage configured to hold a second component and a second radiant energy device. The resin support is configured to be positioned between the second stage and the second radiant energy device. A control system is configured to translate the resin support based on a condition of the first print module and the second print module through the first print module and the second print module.Type: ApplicationFiled: August 9, 2022Publication date: March 2, 2023Inventors: Christopher David Barnhill, Robert Edgar Estes, William Joseph Steele, Trent William Muhlenkamp, Zhen Liu, John Thomas Sterle, Victor Wayne Fulton
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Publication number: 20230051575Abstract: A cleaning system for an additively manufactured component includes a tank storing a cleaning fluid. A fluid circuit is operably coupled with the tank. A pump is coupled with the fluid circuit. A manifold is configured to receive fluid from the fluid circuit through the pump. At least one of a coupler defined by the manifold or a hose is coupled with the manifold. The at least one of the coupler defined by the manifold or the hose is further configured to couple with said additively manufactured component.Type: ApplicationFiled: August 9, 2022Publication date: February 16, 2023Inventors: James Patrick Lewis, Johnny DeLeon, Brian Paul Sechrist, Mary Kathryn Thompson, Christopher David Barnhill, Meredith Elissa Dubelman
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Publication number: 20230050127Abstract: An additive manufacturing apparatus includes a stage configured to hold a component. A radiant energy is device operable to generate and project radiant energy in a patterned image. An actuator is configured to change a position of the stage relative to the radiant energy device. A deposition assembly is upstream of the stage and configured to deposit a resin on a resin support. The deposition assembly includes a reservoir housing configured to retain a volume of resin between the upstream wall and the downstream wall. The deposition assembly also includes an application device operably coupled with the reservoir housing. A computing system is operably coupled with the application device. The computing system is configured to intermittently initiate a flush operation between successive layers of the component, wherein the application device is moved from a first position to a second position during the flush operation.Type: ApplicationFiled: August 9, 2022Publication date: February 16, 2023Inventors: Meredith Elissa Dubelman, Christopher David Barnhill, William Joseph Steele, Xi Yang