Patents by Inventor David M. Keicher

David M. Keicher 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: 10130961
    Abstract: Hydrodynamic focusing of two fluid steams provides a novel micro printing technology for printed electronics and other high performance applications.
    Type: Grant
    Filed: November 5, 2015
    Date of Patent: November 20, 2018
    Assignee: National Technology & Engineering Solutions of Sandia, LLC
    Inventors: David M. Keicher, Adam Cook
  • Patent number: 10058881
    Abstract: The invention provides pneumatic shuttering of a focused or collimated aerosol particle stream. The aerosol stream can be collimated by an annular sheath of inert or non-inert gas. The apparatus propagates a sheathed aerosol stream through a series of aerodynamic lenses along the axis of a flow cell. The final lens is typically positioned above a substrate, so that direct material deposition is provided. A substantially perpendicularly-flowing gas external to the aerodynamic lens system is used to redirect the particle stream away from the flow axis and through an exhaust port, thereby shuttering the collimated aerosol stream. The pneumatic shutter enables printing of discreet structures, with on/off shuttering times of approximately 1 to 100 milliseconds.
    Type: Grant
    Filed: February 27, 2017
    Date of Patent: August 28, 2018
    Assignee: National Technology & Engineering Solutions of Sandia, LLC
    Inventors: David M. Keicher, Adam Cook, Eloy Phillip Baldonado, Marcelino Essien
  • Publication number: 20170057172
    Abstract: A tool path generator with embedded process control commands enables feed-forward process control for additive manufacturing.
    Type: Application
    Filed: August 23, 2016
    Publication date: March 2, 2017
    Inventors: David M. Keicher, Adam Cook
  • Publication number: 20160129634
    Abstract: Hydrodynamic focusing of two fluid steams provides a novel micro printing technology for printed electronics and other high performance applications.
    Type: Application
    Filed: November 5, 2015
    Publication date: May 12, 2016
    Inventors: David M. Keicher, Adam Cook
  • Patent number: 7879394
    Abstract: Method and apparatus for depositing material in hard to reach locations of a workpiece. An elongated member is inserted in an opening. The member transports a laser beam from a fiber laser and material, preferably in powder form, to the desired location. The material is deposited on the workpiece and the laser beam contacts the material. The method and apparatus may be used to manufacture a part or to repair an existing part.
    Type: Grant
    Filed: June 1, 2007
    Date of Patent: February 1, 2011
    Assignee: Optomec, Inc.
    Inventors: David M. Keicher, Lucas B. Brewer, Richard John Grylls
  • Patent number: 6811744
    Abstract: A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer rendering of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head (480) in a directed material deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional processing techniques, is enabled by embedded voids (152) and/or composite materials (126, 127), which include dissimilar metals (210, 216).
    Type: Grant
    Filed: April 22, 2002
    Date of Patent: November 2, 2004
    Assignee: Optomec Design Company
    Inventors: David M. Keicher, James W. Love, Kevin J. Dullea, James L. Bullen, Pierrette H. Gorman, Mark E. Smith
  • Patent number: 6656409
    Abstract: Uniform cooling of complex surface shapes in injection mold tooling can be accomplished with cooling channels that conform to the shapes of the mold cavity or mold cone. By conventional methods this can be very difficult to accomplish. By applying methods of material deposition or material sintering, which include but are not limited to, laser metal deposition, where material is deposited on a layer by layer basis, certain cooling or heating passages could be integrated into the manufactured component that follow the contours and profiles of the mold's complex surfaces. These passages would act as internal heat sinks with a much higher surface area for heat transfer than traditional drilled and plugged straight passages. These geometries could also be incorporated into complex geometries such as, but not limited to, turbine blades where the cooling passages can follow the contour of the outer shape, provide a more uniform or controlled heat transfer from the component.
    Type: Grant
    Filed: July 7, 2000
    Date of Patent: December 2, 2003
    Assignee: Optomec Design Company
    Inventors: David M. Keicher, James W. Love
  • Publication number: 20030206820
    Abstract: A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer renderings of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head (480) in a directed material deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional processing techniques, is enabled by embedded voids (152) and/or composite materials (126, 127), which include dissimilar metals (210, 216).
    Type: Application
    Filed: April 22, 2002
    Publication date: November 6, 2003
    Inventors: David M. Keicher, James W. Love, Kevin J. Dullea, James L. Bullen, Pierrette H. Gorman, Mark E. Smith
  • Publication number: 20020170890
    Abstract: This invention combines the precision spray process with in-flight laser treatment in order to produce direct write electronic components. In addition to these components, the process can lay down lines of conductive, inductive, and resistive materials. This development has the potential to change the approach to electronics packaging. This process is revolutionary in that components can be directly produced on small structures, thus removing the need for printed circuit boards.
    Type: Application
    Filed: April 27, 2001
    Publication date: November 21, 2002
    Inventors: David M. Keicher, W. Doyle Miller, Marcelino Essien
  • Patent number: 6476343
    Abstract: An energy beam driven rapid fabrication system, in which an energy beam strikes a growth surface to form a molten puddle thereon. Feed powder is then injected into the molten puddle from a converging flow of feed powder. A portion of the feed powder becomes incorporated into the molten puddle, forcing some of the puddle contents to freeze on the growth surface, thereby adding an additional layer of material. By scanning the energy beam and the converging flow of feed powder across the growth surface, complex three-dimensional shapes can be formed, ready or nearly ready for use. Nearly any class of material can be fabricated using this system.
    Type: Grant
    Filed: April 24, 1998
    Date of Patent: November 5, 2002
    Assignee: Sandia Corporation
    Inventors: David M. Keicher, Clinton L. Atwood, Donald L. Greene, Michelle L. Griffith, Lane D. Harwell, Francisco P. Jeantette, Joseph A. Romero, Lee P. Schanwald, David T. Schmale
  • Patent number: 6391251
    Abstract: A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer renderings of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head (480) in a directed material deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional processing techniques, is enabled by embedded voids (152) and/or composite materials (126, 127), which include dissimilar metals (210, 216).
    Type: Grant
    Filed: May 9, 2000
    Date of Patent: May 21, 2002
    Assignee: Optomec Design Company
    Inventors: David M. Keicher, James L. Bullen, Pierrette H. Gorman, James W. Love, Kevin J. Dullea, Mark E. Smith
  • Publication number: 20020051853
    Abstract: A method has been developed to exploit the desirable material and process characteristics provided by a low powered laser material deposition system, while overcoming the low material deposition rate imposed by the same process. One application of particular importance for this invention is direct fabrication of functional, solid objects from a CAD solid model This method of fabrication uses a software interpreter to electronically slice the CAD model into thin horizontal layers that are subsequently used to drive the deposition apparatus. The apparatus uses a single laser beam to outline the features of the solid object and then uses a series of equally spaced laser beams to quickly fill in the featureless regions. Using the lower powered laser provides the ability to create a part that is very accurate, with material properties that meet or exceed that of a conventionally processed and annealed specimen of similar composition.
    Type: Application
    Filed: April 24, 2001
    Publication date: May 2, 2002
    Inventors: David M. Keicher, W. Doyle Miller
  • Patent number: 6268584
    Abstract: A method has been developed to exploit the desirable material and process characteristics provided by a low powered laser material deposition system, while overcoming the low material deposition rate imposed by the same process. One application of particular importance for this invention is direct fabrication of functional, solid objects from a CAD solid model. This method of fabrication uses a software interpreter to electronically slice the CAD model into thin horizontal layers that are subsequently used to drive the deposition apparatus. The apparatus uses a single laser beam to outline the features of the solid object and then uses a series of equally spaced laser beams to quickly fill in the featureless regions. Using the lower powered laser provides the ability to create a part that is very accurate, with material properties that meet or exceed that of a conventionally processed and annealed specimen of similar composition.
    Type: Grant
    Filed: July 20, 1998
    Date of Patent: July 31, 2001
    Assignee: Optomec Design Company
    Inventors: David M. Keicher, W. Doyle Miller
  • Publication number: 20010008230
    Abstract: An energy beam driven rapid fabrication system, in which an energy beam strikes a growth surface to form a molten puddle thereon. Feed powder is then injected into the molten puddle from a converging flow of feed powder. A portion of the feed powder becomes incorporated into the molten puddle, forcing some of the puddle contents to freeze on the growth surface, thereby adding an additional layer of material. By scanning the energy beam and the converging flow of feed powder across the growth surface, complex three-dimensional shapes can be formed, ready or nearly ready for use. Nearly any class of material can be fabricated using this invention.
    Type: Application
    Filed: April 24, 1998
    Publication date: July 19, 2001
    Inventors: DAVID M. KEICHER, CLINTON L. ATWOOD, DONALD L. GREENE, MICHELLE L. GRIFFITH, LANE D. HARWELL, FRANCISCO P. JEANTETTE, JOSEPH A. ROMERO, LEE P. SCHANWALD, DAVID T. SCHMALE
  • Patent number: 6251488
    Abstract: This invention combines the precision spray process with in-flight laser treatment in order to produce direct write electronic components. In addition to these components, the process can lay down lines of conductive, inductive, and resistive materials. This development has the potential to change the approach to electronics packaging. This process is revolutionary in that components can be directly produced on small structures, thus removing the need for printed circuit boards.
    Type: Grant
    Filed: May 5, 1999
    Date of Patent: June 26, 2001
    Assignee: Optomec Design Company
    Inventors: W. Doyle Miller, David M. Keicher, Marcelino Essien
  • Patent number: 6075220
    Abstract: An apparatus and method for determining the penetration of the weld pool created from pulsed laser welding and more particularly to an apparatus and method of utilizing an optical technique to monitor the weld vaporization plume velocity to determine the depth of penetration. A light source directs a beam through a vaporization plume above a weld pool, wherein the plume changes the intensity of the beam, allowing determination of the velocity of the plume. From the velocity of the plume, the depth of the weld is determined.
    Type: Grant
    Filed: February 12, 1998
    Date of Patent: June 13, 2000
    Assignee: Sandia Corporation
    Inventors: Marcelino Essien, David M. Keicher, M. Eric Schlienger, James L. Jellison
  • Patent number: 6046426
    Abstract: A method and system are provided for producing complex, three-dimensional, net shape objects from a variety of powdered materials. The system includes unique components to ensure a uniform and continuous flow of powdered materials as well as to focus and locate the flow of powdered materials with respect to a laser beam which results in the melting of the powdered material. The system also includes a controller so that the flow of molten powdered materials can map out and form complex, three-dimensional, net-shape objects by layering the molten powdered material. Advantageously, such complex, three-dimensional net-shape objects can be produced having material densities varying from 90% of theoretical to fully dense, as well as a variety of controlled physical properties. Additionally, such complex, three-dimensional objects can be produced from two or more different materials so that the composition of the object can be transitioned from one material to another.
    Type: Grant
    Filed: July 8, 1996
    Date of Patent: April 4, 2000
    Assignee: Sandia Corporation
    Inventors: Francisco P. Jeantette, David M. Keicher, Joseph A. Romero, Lee P. Schanwald
  • Patent number: 5993554
    Abstract: An apparatus and method have been developed to exploit the desirable material and process characteristics provided by a low powered laser material deposition system, while overcoming the low material deposition rate imposed by the same process. One application of particular importance for this invention is direct fabrication of functional, solid objects from a CAD solid model. This apparatus uses a software interpreter to electronically slice the CAD model into thin horizontal layers that are subsequently used to drive the deposition apparatus. This apparatus uses a single laser beam to outline the features of the solid object and then uses a series of equally spaced laser beams to quickly fill in the featureless regions. Using the lower powered laser provides the ability to create a part that is very accurate, with material properties that meet or exceed that of a conventionally processed and annealed specimen of similar composition.
    Type: Grant
    Filed: January 22, 1998
    Date of Patent: November 30, 1999
    Assignee: Optemec Design Company
    Inventors: David M. Keicher, W. Doyle Miller
  • Patent number: 4992643
    Abstract: A method and apparatus for enhancing the weldment of a laser welding system is provided. The laser weld plume control device includes a cylindrical body defining an upside-down cone cavity; the upper surface of the body circumscribes the base of the cone cavity, and the vertex of the cone cavity forms an orifice concentrically located with respect to the laser beam and the plume which forms as a result of the welding operation. According to the method of the invention, gas is directed radially inward through inlets in the upper surface of the body into and through channels in the wall of the body and finally through the orifice of the body, and downward onto the surface of the weldment. The gas flow is then converted by the orifice of the device from radial flow to an axisymmetric gas jet flowing away from the weldment surface in a direction perpendicular to the surface and opposite to that of the laser.
    Type: Grant
    Filed: August 25, 1989
    Date of Patent: February 12, 1991
    Assignee: United States Department of Energy
    Inventors: Phillip W. Fuerschbach, James L. Jellison, David M. Keicher, William L. Oberkampf