Patents by Inventor David Charles Bogdan, Jr.
David Charles Bogdan, Jr. 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: 11712765Abstract: A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.Type: GrantFiled: August 9, 2021Date of Patent: August 1, 2023Assignee: General Electric CompanyInventors: David Charles Bogdan, Jr., Jason Harris Karp, William Thomas Carter
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Patent number: 11571743Abstract: In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.Type: GrantFiled: November 13, 2017Date of Patent: February 7, 2023Assignee: General Electric CompanyInventors: Michael Evans Graham, William Monaghan, Thomas Charles Adcock, Andrew J. Martin, John Joseph Madelone, Jr., David Charles Bogdan, Jr., John Broddus Deaton, Jr., William Thomas Carter
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Publication number: 20230030701Abstract: An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.Type: ApplicationFiled: October 12, 2022Publication date: February 2, 2023Inventors: William Thomas Carter, Justin John Gambone, JR., Lang Yuan, David Charles Bogdan, JR., Marshall Gordon Jones
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Patent number: 11484970Abstract: An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.Type: GrantFiled: February 21, 2017Date of Patent: November 1, 2022Assignee: General Electric CompanyInventors: William Thomas Carter, Justin John Gambone, Jr., Lang Yuan, David Charles Bogdan, Jr., Marshall Gordon Jones
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Publication number: 20210370448Abstract: A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.Type: ApplicationFiled: August 9, 2021Publication date: December 2, 2021Inventors: David Charles Bogdan, JR., Jason Harris Karp, William Thomas Carter
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Patent number: 11152648Abstract: A positive electrode composition is described, containing granules of at least one electroactive metal, at least one alkali metal halide and carbon black. An energy storage device and an uninterruptable power supply device are also described. Related methods for the preparation of a positive electrode and an energy storage device are also disclosed.Type: GrantFiled: October 23, 2015Date of Patent: October 19, 2021Assignee: GENERAL ELECTRIC COMPANYInventors: Brandon Alan Bartling, Michael Alan Vallance, Richard Louis Hart, David Charles Bogdan, Jr.
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Patent number: 11141818Abstract: A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.Type: GrantFiled: February 5, 2018Date of Patent: October 12, 2021Assignee: General Electric CompanyInventors: William Thomas Carter, Todd Jay Rockstroh, Brian Scott McCarthy, Subhrajit Roychowdhury, Younkoo Jeong, David Charles Bogdan, Jr.
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Patent number: 11084132Abstract: A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.Type: GrantFiled: October 26, 2017Date of Patent: August 10, 2021Assignee: General Electric CompanyInventors: David Charles Bogdan, Jr., Jason Harris Karp, William Thomas Carter
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Patent number: 10906132Abstract: An additive manufacturing system configured to manufacture a component including scan strategies for efficient utilization of one or more laser arrays. The additive manufacturing system includes at least one laser device, each configured as a laser array, and a build platform. Each laser device is configured to generate a plurality of laser beams. The component is disposed on the build platform. The at least one laser device is configured to sweep across the component and the build platform in at least one of a radial direction, a circumferential direction or a modified zig-zag pattern and simultaneously operate the one or more of the plurality of individually operable laser beams corresponding to a pattern of the layer of a build to generate successive layers of a melted powdered material on the component and the build platform corresponding to the pattern of the layer of the build. A method of manufacturing a component with the additive manufacturing system is also disclosed.Type: GrantFiled: March 31, 2017Date of Patent: February 2, 2021Assignee: General Electric CompanyInventors: William Thomas Carter, Jason Harris Karp, Justin John Gambone, Jr., Lang Yuan, David Charles Bogdan, Jr., Victor Petrovish Ostroverkhov, Marshall Gordon Jones, Michael Evans Graham, Kevin George Harding
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Patent number: 10583530Abstract: A component is fabricated in a powder bed by moving a laser array across the powder bed. The laser array includes a plurality of laser devices. The power output of each laser device of the plurality of laser devices is independently controlled. The laser array emits a plurality of energy beams from a plurality of selected laser devices of the plurality of laser devices to generate a melt pool in the powder bed. A non-uniform energy intensity profile is generated by the plurality of selected laser devices. The non-uniform energy intensity profile facilitates generating a melt pool that has a predetermined characteristic.Type: GrantFiled: January 9, 2017Date of Patent: March 10, 2020Assignee: General Electric CompanyInventors: Jason Harris Karp, Justin John Gambone, Jr., Michael Evans Graham, David Charles Bogdan, Jr., Victor Petrovich Ostroverkhov, William Thomas Carter, Harry Kirk Mathews, Jr., Kevin George Harding, Jinjie Shi, Marshall Gordon Jones, James William Sears
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Patent number: 10569364Abstract: A recoating device for an additive manufacturing system includes a plurality of recoater blades which include a first stage and a second stage. The first stage includes a plurality of rows of the plurality of recoater blades and extends in the transverse dimension. The second stage includes a plurality of recoater blades and is configured substantially similar to the first stage of the plurality of recoater blades. The second stage of recoater blades is displaced from the first stage of recoater blades in the vertical dimension.Type: GrantFiled: January 6, 2017Date of Patent: February 25, 2020Assignee: General Electric CompanyInventors: Jinjie Shi, David Charles Bogdan, Jr., William Thomas Carter, Christopher James Hayden
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Patent number: 10502701Abstract: An additive manufacturing system includes a cabinet, an electron beam system, at least one imaging device, and a computing device. The cabinet is configured to enclose a component and defines a pinhole extending therethrough. The electron beam system is configured to generate an electron beam directed toward the component. Interactions between the component and the electron beam generate x-ray radiation. The at least one imaging device is configured to detect the x-ray radiation through the pinhole. The computing device is configured to image the component based on the x-ray radiation detected by the at least one imaging device.Type: GrantFiled: March 30, 2018Date of Patent: December 10, 2019Assignee: General Electric CompanyInventors: Vladimir Anatolievich Lobastov, Adrian Ivan, David Charles Bogdan, Jr.
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Patent number: 10500832Abstract: An additive manufacturing system is configured to manufacture a component. The additive manufacturing system includes a laser device, a build platform, a first scanning device, and an air knife. The laser device is configured to generate a laser beam. The component is disposed on the build platform. The air knife is configured to channel an inert gas across the build platform. The first scanning device is configured to selectively direct the laser beam across the build platform. The laser beam is configured to generate successive layers of a melted powdered build material on the component and the build platform. The build platform is configured to rotate the component relative to the air knife.Type: GrantFiled: January 18, 2017Date of Patent: December 10, 2019Assignee: General Electric CompanyInventors: David Charles Bogdan, Jr., Jason Harris Karp, Justin John Gambone, Jr., Lang Yuan, Jinjie Shi, Victor Petrovich Ostroverkhov, Marshall Gordon Jones, William Thomas Carter, Harry Kirk Mathews, Jr., Kevin George Harding
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Publication number: 20190302043Abstract: An additive manufacturing system includes a cabinet, an electron beam system, at least one imaging device, and a computing device. The cabinet is configured to enclose a component and defines a pinhole extending therethrough. The electron beam system is configured to generate an electron beam directed toward the component. Interactions between the component and the electron beam generate x-ray radiation. The at least one imaging device is configured to detect the x-ray radiation through the pinhole. The computing device is configured to image the component based on the x-ray radiation detected by the at least one imaging device.Type: ApplicationFiled: March 30, 2018Publication date: October 3, 2019Inventors: Vladimir Anatolievich Lobastov, Adrian Ivan, David Charles Bogdan, JR.
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Publication number: 20190240781Abstract: A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.Type: ApplicationFiled: February 5, 2018Publication date: August 8, 2019Inventors: William Thomas Carter, Todd Jay Rockstroh, Brian Scott McCarthy, Subhrajit Roychowdhury, Younkoo Jeong, David Charles Bogdan, JR.
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Publication number: 20190210151Abstract: A pressurized consolidation assembly for an additive manufacturing system is provided. The pressurized consolidation assembly defines a first direction, a second direction, and a third direction, the three directions orthogonal to each other. The pressurized consolidation assembly includes a build platform configured to hold a plurality of particles and a pressure chamber surrounding the build platform. The pressure chamber is configured to retain a first volume of a gas having a first pressure. The pressure chamber includes an energy beam window. The energy beam window extends through a first section of the pressure chamber and is configured to enable an energy beam to pass through the energy beam window to be incident on the plurality of particles on the build platform.Type: ApplicationFiled: January 8, 2018Publication date: July 11, 2019Inventors: Andrew David Deal, Evan Dozier, Scott Michael Oppenheimer, Jason Harris Karp, David Charles Bogdan, JR.
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Patent number: 10333184Abstract: The present disclosure is directed to a heat flux assembly for an energy storage device. The energy storage device includes a housing with a plurality of side walls that define an internal volume and a plurality of cells configured within the internal volume. The heat flux assembly includes a plurality of heat flux components configured for arrangement with the side walls of the housing of the energy storage device and one or more temperature sensors configured with each of the plurality of heat flux components. Thus, the temperature sensors are configured to monitor one or more temperatures at various locations in the plurality of heat flux components. The heat flux assembly also includes a controller configured to adjust a power level of each of the heat flux components as a function of the monitored temperature so as to reduce a temperature gradient or difference across the plurality of cells during operation of the energy storage device.Type: GrantFiled: September 9, 2015Date of Patent: June 25, 2019Assignee: General Electric CompanyInventors: Kristopher John Frutschy, James S. Lindsey, David Charles Bogdan, Jr., James Thorpe Browell, Patrick Daniel Willson, Amin Ajdari, Narayan Subramanian, Michael Stanley Zanoni, Lukas Mercer Hansen
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Publication number: 20190143406Abstract: An additive manufacturing apparatus includes first and second spaced apart side walls defining a build chamber therebetween. The first and second spaced apart side walls are configured to rotate through an angle ?, about a z-axis along a pre-defined path. A build platform is defined within the first and second spaced apart side walls and is configured to rotate through an angle ? about the z-axis and vertically moveable along the z-axis. The apparatus further includes one or more build units mounted for movement along the pre-defined path. An additive manufacturing method is additionally disclosed.Type: ApplicationFiled: November 13, 2017Publication date: May 16, 2019Inventors: William Thomas Carter, David Charles Bogdan, JR., Jason Harris Karp, Justin John Gambone, JR., Victor Petrovich Ostroverkhov, Marshall Gordon Jones, Kevin George Harding, Younkoo Jeong, Michael Robert Tucker, Subhrajit Roychowdhury
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Publication number: 20190143408Abstract: In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.Type: ApplicationFiled: November 13, 2017Publication date: May 16, 2019Inventors: Michael Evans Graham, William Monaghan, Thomas Charles Adcock, Andrew J. Martin, John Joseph Madelone, Jr., David Charles Bogdan, Jr., John Broddus Deaton, Jr., William Thomas Carter
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Publication number: 20190126413Abstract: A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.Type: ApplicationFiled: October 26, 2017Publication date: May 2, 2019Inventors: David Charles Bogdan, JR., Jason Harris Karp, William Thomas Carter