Patents by Inventor Christopher F. O'Neill

Christopher F. O'Neill 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).

  • Patent number: 10953470
    Abstract: An additive manufacturing machine includes an energy unit with two energy beam sources, each with a different power level of energy beam. In addition, a build unit receives the energy beams, and a reflecting unit is positioned between the energy unit and the build unit and directs the energy beams. There is also an energy beam detector positioned on or near the build unit.
    Type: Grant
    Filed: August 31, 2016
    Date of Patent: March 23, 2021
    Assignee: Raytheon Technologies Corporation
    Inventor: Christopher F. O'Neill
  • Patent number: 10913258
    Abstract: An additive manufacturing process includes simultaneously constructing a component and a non-contacting thermal support for the component. The non-contacting thermal support includes a three dimensional negative of the component. The non-contacting thermal support transfers heat from the component into a heat sink.
    Type: Grant
    Filed: February 2, 2015
    Date of Patent: February 9, 2021
    Assignee: Raytheon Technologies Corporation
    Inventors: Adam Z. Doherty, Christopher F. O'Neill, John P. Rizzo, Jr.
  • Patent number: 10888924
    Abstract: A powder processing machine includes a work bed, a powder deposition device operable to deposit powder in the work bed, at least one energy beam device operable to emit an energy beam with a variable beam power and direct the energy beam onto the work bed with a variable beam scan rate to melt and fuse regions of the powder, and a controller operable to dynamically control at least one of the beam power or the beam scan rate to change how the powder melts and fuses. The controller is configured to determine whether an instant set of process parameters falls within a defect condition or a non-defect condition and adjust at least one of the beam power or the beam scan rate responsive to the defect condition such that the instant set of process parameters falls within the non-defect condition.
    Type: Grant
    Filed: January 26, 2018
    Date of Patent: January 12, 2021
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventors: Sergei F. Burlatsky, David Ulrich Furrer, Rebecca L. Runkle, Jesse R. Boyer, Christopher F. O'Neill
  • Publication number: 20200254525
    Abstract: An additively manufactured assembly including an additively manufactured component with an edge oriented with respect to a recoater blade direction and an non-contact support that does not form a part of the additively manufactured component, the additively manufactured support located adjacent the edge. A method of additively manufacturing a component includes additively manufacturing an component with an edge oriented with respect to a recoater blade direction simultaneous with additively manufacturing an non-contact support that does not form a part of the component, the additively manufactured support located adjacent the edge.
    Type: Application
    Filed: April 28, 2020
    Publication date: August 13, 2020
    Applicant: Raytheon Technologies Corporation
    Inventors: Adam Z. Doherty, Christopher F. O'Neill, John P. Rizzo
  • Patent number: 10668532
    Abstract: An additively manufactured assembly including an additively manufactured component with an edge oriented with respect to a recoater blade direction and an non-contact support that does not form a part of the additively manufactured component, the additively manufactured support located adjacent the edge. A method of additively manufacturing a component includes additively manufacturing an component with an edge oriented with respect to a recoater blade direction simultaneous with additively manufacturing an non-contact support that does not form a part of the component, the additively manufactured support located adjacent the edge.
    Type: Grant
    Filed: February 12, 2015
    Date of Patent: June 2, 2020
    Assignee: Raytheon Technologies Corporation
    Inventors: Adam Z Doherty, Christopher F O'Neill, John P Rizzo, Jr.
  • Patent number: 10549520
    Abstract: A structure includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.
    Type: Grant
    Filed: October 7, 2016
    Date of Patent: February 4, 2020
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Sergey Mironets, Lyutsia Dautova, Joseph Ott, Christopher F. O'Neill, Robert P. Delisle, Jesse R. Boyer, Agnes Klucha, Louis Porretti
  • Publication number: 20190358948
    Abstract: An additive manufacturing system can include a powder dispenser; a gate adjacent to the powder dispenser; a recoater blade system; and a control operable to move the gate with respect to the powder dispenser to selectively dispense powder from the powder dispenser.
    Type: Application
    Filed: August 7, 2019
    Publication date: November 28, 2019
    Applicant: United Technologies Corporation
    Inventors: Christopher F. O'Neill, Jesse R. Boyer, Anthony Pizzola
  • Patent number: 10414148
    Abstract: An additive manufacturing system can include a powder dispenser; a gate adjacent to the powder dispenser; a recoater blade system; and a control operable to move the gate with respect to the powder dispenser to selectively dispense powder from the powder dispenser.
    Type: Grant
    Filed: November 16, 2016
    Date of Patent: September 17, 2019
    Assignee: United Technologies Corporation
    Inventors: Christopher F. O'Neill, Jesse R. Boyer, Anthony Pizzola
  • Publication number: 20190242865
    Abstract: A system includes a build plate, at least one component that is additively manufactured on the build plate from a powder material, and at least one capsule that is additively manufactured on the build plate from the same powder material. The capsule includes an additively manufactured core that is representative of one or more scaled build configuration layers of the at least one component and an arrangement of the layers on the build plate, a sample of unused powder material, and a shell that at least partially encloses the core and the sample.
    Type: Application
    Filed: February 2, 2018
    Publication date: August 8, 2019
    Inventors: Michael W. Bennett, Thomas A. Rebbecchi, Christopher F. O'Neill, Jesse R. Boyer
  • Publication number: 20190015923
    Abstract: An additively manufactured element includes a support structure connected to an article body. The connectors connecting the support structure to the article body are fused supports. Also disclosed is a method for removing the support structure from the article body by passing an electrical current through the fused supports, thereby breaking the fused supports.
    Type: Application
    Filed: July 11, 2017
    Publication date: January 17, 2019
    Inventors: Christopher F. O'Neill, Jesse R. Boyer
  • Publication number: 20180229303
    Abstract: A powder processing machine includes a work bed, a powder deposition device operable to deposit powder in the work bed, at least one energy beam device operable to emit an energy beam with a variable beam power and direct the energy beam onto the work bed with a variable beam scan rate to melt and fuse regions of the powder, and a controller operable to dynamically control at least one of the beam power or the beam scan rate to change how the powder melts and fuses. The controller is configured to determine whether an instant set of process parameters falls within a defect condition or a non-defect condition and adjust at least one of the beam power or the beam scan rate responsive to the defect condition such that the instant set of process parameters falls within the non-defect condition.
    Type: Application
    Filed: January 26, 2018
    Publication date: August 16, 2018
    Inventors: Sergei F. Burlatsky, David Ulrich Furrer, Rebecca L. Runkle, Jesse R. Boyer, Christopher F. O'Neill
  • Publication number: 20180134027
    Abstract: An additive manufacturing system can include a powder dispenser; a gate adjacent to the powder dispenser; a recoater blade system; and a control operable to move the gate with respect to the powder dispenser to selectively dispense powder from the powder dispenser.
    Type: Application
    Filed: November 16, 2016
    Publication date: May 17, 2018
    Applicant: United Technologies Corporation
    Inventors: Christopher F. O'Neill, Jesse R. Boyer, Anthony Pizzola
  • Publication number: 20180056390
    Abstract: An additive manufacturing machine includes an energy unit with two energy beam sources, each with a different power level of energy beam. In addition, a build unit receives the energy beams, and a reflecting unit is positioned between the energy unit and the build unit and directs the energy beams. There is also an energy beam detector positioned on or near the build unit.
    Type: Application
    Filed: August 31, 2016
    Publication date: March 1, 2018
    Inventor: Christopher F. O'Neill
  • Patent number: 9778150
    Abstract: A method of obtaining a sample of materials includes building a product through an additive manufacturing process. A capsule is formed with an internal chamber inside of the capsule. The capsule is formed during the building of the additive manufacturing product. A sample of powder is encapsulated inside the internal chamber as the capsule is built. The internal chamber is hermetically sealed from an exterior environment to retain the sample of powder in the internal chamber.
    Type: Grant
    Filed: March 21, 2014
    Date of Patent: October 3, 2017
    Assignee: United Technologies Corporation
    Inventor: Christopher F. O'Neill
  • Publication number: 20170021606
    Abstract: A structure includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.
    Type: Application
    Filed: October 7, 2016
    Publication date: January 26, 2017
    Inventors: Sergey Mironets, Lyutsia Dautova, Joseph Ott, Christopher F. O'Neill, Robert P. Delisle, Jesse R. Boyer, Agnes Klucha, Louis Porretti
  • Patent number: 9539764
    Abstract: A component includes a support structure made with an additive manufacturing process with a first end and a second end, and an object made with an additive manufacturing process with a first end and a second end, where the first end of the object is attached to the second end of the support structure. A cross-sectional area of the first end of the object is larger than a cross-sectional area of the second end of the support structure. A method of making an object, the method includes manufacturing a support structure with an additive manufacturing process. An object is manufactured on top of and connected to the support structure with an additive manufacturing process, wherein there is a witness mark created between the support structure and the object. The witness mark is identified. The object is separated from the support structure along the witness mark.
    Type: Grant
    Filed: March 13, 2014
    Date of Patent: January 10, 2017
    Assignee: United Technologies Corporation
    Inventors: Ronald R. Soucy, Christopher F. O'Neill, Robert P. Delisle
  • Patent number: 9533372
    Abstract: A method for operating an additive manufacturing apparatus, the method comprises directing a first energy beam along a surface contour vector in a build plane. A second energy beam is directed along a plurality of substantially parallel hatch vectors disposed in the build plane inward of the surface contour vector. A sum of the surface contour vector and the plurality of hatch vectors define a processed powder region in the build plane. A third energy beam is directed along an offset contour vector in the build plane. The offset contour vector includes a plurality of unprocessed powder regions in the build plane between the surface contour vector and the plurality of hatch vectors.
    Type: Grant
    Filed: May 2, 2014
    Date of Patent: January 3, 2017
    Assignee: United Technologies Corporation
    Inventor: Christopher F. O'Neill
  • Patent number: 9486963
    Abstract: A powder-derived, non-finished work piece includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.
    Type: Grant
    Filed: December 28, 2012
    Date of Patent: November 8, 2016
    Assignee: United Technologies Corporation
    Inventors: Sergey Mironets, Lyutsia Dautova, Joseph Ott, Christopher F. O'Neill, Robert P. Delisle, Jesse R. Boyer, Agnes Klucha, Louis Porretti
  • Publication number: 20160236277
    Abstract: An additively manufactured assembly including an additively manufactured component with an edge oriented with respect to a recoater blade direction and an non-contact support that does not form a part of the additively manufactured component, the additively manufactured support located adjacent the edge. A method of additively manufacturing a component includes additively manufacturing an component with an edge oriented with respect to a recoater blade direction simultaneous with additively manufacturing an non-contact support that does not form a part of the component, the additively manufactured support located adjacent the edge.
    Type: Application
    Filed: February 12, 2015
    Publication date: August 18, 2016
    Inventors: ADAM Z. DOHERTY, CHRISTOPHER F. O'NEILL, JOHN P. RIZZO, JR.
  • Publication number: 20160221264
    Abstract: An additive manufacturing process includes simultaneously constructing a component and a non-contacting thermal support for the component. The non-contacting thermal support includes a three dimensional negative of the component. The non-contacting thermal support transfers heat from the component into a heat sink.
    Type: Application
    Filed: February 2, 2015
    Publication date: August 4, 2016
    Inventors: Adam Z. Doherty, Christopher F. O'Neill, John P. Rizzo, JR.