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).
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Patent number: 11565326Abstract: 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: GrantFiled: April 28, 2020Date of Patent: January 31, 2023Assignee: Raytheon Technologies CorporationInventors: Adam Z. Doherty, Christopher F. O'Neill, John P. Rizzo, Jr.
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Patent number: 11260649Abstract: 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: GrantFiled: August 7, 2019Date of Patent: March 1, 2022Assignee: Raytheon Technologies CorporationInventors: Christopher F. O'Neill, Jesse R. Boyer, Anthony Pizzola
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Patent number: 10953470Abstract: 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: GrantFiled: August 31, 2016Date of Patent: March 23, 2021Assignee: Raytheon Technologies CorporationInventor: Christopher F. O'Neill
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Patent number: 10913258Abstract: 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: GrantFiled: February 2, 2015Date of Patent: February 9, 2021Assignee: Raytheon Technologies CorporationInventors: Adam Z. Doherty, Christopher F. O'Neill, John P. Rizzo, Jr.
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Patent number: 10888924Abstract: 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: GrantFiled: January 26, 2018Date of Patent: January 12, 2021Assignee: RAYTHEON TECHNOLOGIES CORPORATIONInventors: Sergei F. Burlatsky, David Ulrich Furrer, Rebecca L. Runkle, Jesse R. Boyer, Christopher F. O'Neill
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Publication number: 20200254525Abstract: 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: ApplicationFiled: April 28, 2020Publication date: August 13, 2020Applicant: Raytheon Technologies CorporationInventors: Adam Z. Doherty, Christopher F. O'Neill, John P. Rizzo
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Patent number: 10668532Abstract: 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: GrantFiled: February 12, 2015Date of Patent: June 2, 2020Assignee: Raytheon Technologies CorporationInventors: Adam Z Doherty, Christopher F O'Neill, John P Rizzo, Jr.
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Patent number: 10549520Abstract: 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: GrantFiled: October 7, 2016Date of Patent: February 4, 2020Assignee: UNITED TECHNOLOGIES CORPORATIONInventors: Sergey Mironets, Lyutsia Dautova, Joseph Ott, Christopher F. O'Neill, Robert P. Delisle, Jesse R. Boyer, Agnes Klucha, Louis Porretti
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Publication number: 20190358948Abstract: 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: ApplicationFiled: August 7, 2019Publication date: November 28, 2019Applicant: United Technologies CorporationInventors: Christopher F. O'Neill, Jesse R. Boyer, Anthony Pizzola
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Patent number: 10414148Abstract: 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: GrantFiled: November 16, 2016Date of Patent: September 17, 2019Assignee: United Technologies CorporationInventors: Christopher F. O'Neill, Jesse R. Boyer, Anthony Pizzola
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Publication number: 20190242865Abstract: 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: ApplicationFiled: February 2, 2018Publication date: August 8, 2019Inventors: Michael W. Bennett, Thomas A. Rebbecchi, Christopher F. O'Neill, Jesse R. Boyer
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Publication number: 20190015923Abstract: 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: ApplicationFiled: July 11, 2017Publication date: January 17, 2019Inventors: Christopher F. O'Neill, Jesse R. Boyer
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Publication number: 20180229303Abstract: 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: ApplicationFiled: January 26, 2018Publication date: August 16, 2018Inventors: Sergei F. Burlatsky, David Ulrich Furrer, Rebecca L. Runkle, Jesse R. Boyer, Christopher F. O'Neill
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Publication number: 20180134027Abstract: 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: ApplicationFiled: November 16, 2016Publication date: May 17, 2018Applicant: United Technologies CorporationInventors: Christopher F. O'Neill, Jesse R. Boyer, Anthony Pizzola
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Publication number: 20180056390Abstract: 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: ApplicationFiled: August 31, 2016Publication date: March 1, 2018Inventor: Christopher F. O'Neill
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Patent number: 9778150Abstract: 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: GrantFiled: March 21, 2014Date of Patent: October 3, 2017Assignee: United Technologies CorporationInventor: Christopher F. O'Neill
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Publication number: 20170021606Abstract: 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: ApplicationFiled: October 7, 2016Publication date: January 26, 2017Inventors: Sergey Mironets, Lyutsia Dautova, Joseph Ott, Christopher F. O'Neill, Robert P. Delisle, Jesse R. Boyer, Agnes Klucha, Louis Porretti
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Patent number: 9539764Abstract: 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: GrantFiled: March 13, 2014Date of Patent: January 10, 2017Assignee: United Technologies CorporationInventors: Ronald R. Soucy, Christopher F. O'Neill, Robert P. Delisle
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Patent number: 9533372Abstract: 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: GrantFiled: May 2, 2014Date of Patent: January 3, 2017Assignee: United Technologies CorporationInventor: Christopher F. O'Neill
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Patent number: 9486963Abstract: 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: GrantFiled: December 28, 2012Date of Patent: November 8, 2016Assignee: United Technologies CorporationInventors: Sergey Mironets, Lyutsia Dautova, Joseph Ott, Christopher F. O'Neill, Robert P. Delisle, Jesse R. Boyer, Agnes Klucha, Louis Porretti