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).
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Patent number: 11717892Abstract: Hybrid additive featured plates used to form an overall microchannel heat exchanger and corresponding method of manufacture are disclosed. Various additive manufacturing (AM) techniques may be used to form walls defining microchannel features on a plate substrate. The manufacturing method is a hybrid process in that leverages both additive and conventional manufacturing techniques to minimize both cost and fabrication time.Type: GrantFiled: August 31, 2021Date of Patent: August 8, 2023Assignees: National Technology & Engineering Solutions of Sandia, LLC, Vacuum Process Engineering, Inc.Inventors: Matthew David Carlson, Yasmin Dennig, Judith Maria Lavin, David M. Keicher, Carl Schalansky
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Publication number: 20220410579Abstract: An aerosol-based printing apparatus is provided capable of producing an aerosol stream at a constant rate and constant material deposition to a substrate to provide high-definition, high-resolution traces. The aerosol-based printing apparatus provides production, transport, and delivery of an aerosol stream at a constant rate for a period of time of at least 8 hours and other instances more than 24 continuous hours of constant operation. By inhibiting bulging and necking of the deposited trace, superior line width tolerances are achieved, and such tolerances are maintained for extended periods of time, thereby allowing for both the deposition of complex traces as well as consistent manufacture of duplicate articles that maintain the tolerances across a production ran. The accumulation of fluids in the aerosol and gas transport conduits are eliminated, thereby eliminating the need for purge or cleaning cycles and allowing for uninterrupted operation for a minimum of 24 hours.Type: ApplicationFiled: September 25, 2020Publication date: December 29, 2022Applicant: INTEGRATED DEPOSITION SOLUTIONS, INC.Inventors: Marcelino Essien, David M. Keicher
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HIGH-DEFINITION AEROSOL PRINTING USING AN OPTIMIZED AEROSOL DISTRIBUTION AND AERODYNAMIC LENS SYSTEM
Publication number: 20220088925Abstract: An apparatus for printing discrete high-resolution high-density features on a surface is provided using an aerosol stream. An aerosol chamber has a transport gas that enters through a port and entrains aerosol in an aerosol chamber to form an aerosol-laden transport gas. A flow cell is provided that has a flow cell channel and sheath gas conduits. The aerosol-laden transport gas passes through the flow cell channel and is surrounded by sheath gas passed through the sheath gas conduits. At least one aerodynamic lens receives the aerosol-laden transport gas surrounded by sheath gas. A method of printing the aerosol droplets from the aerosol-laden transport gas onto the substrate with a mean diameter of 0.5 to 8 microns is also provided.Type: ApplicationFiled: September 21, 2021Publication date: March 24, 2022Applicant: Integrated Deposition Solutions, Inc.Inventors: Marcelino Essien, David M. Keicher -
Patent number: 10130961Abstract: Hydrodynamic focusing of two fluid steams provides a novel micro printing technology for printed electronics and other high performance applications.Type: GrantFiled: November 5, 2015Date of Patent: November 20, 2018Assignee: National Technology & Engineering Solutions of Sandia, LLCInventors: David M. Keicher, Adam Cook
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Patent number: 10058881Abstract: 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: GrantFiled: February 27, 2017Date of Patent: August 28, 2018Assignee: National Technology & Engineering Solutions of Sandia, LLCInventors: David M. Keicher, Adam Cook, Eloy Phillip Baldonado, Marcelino Essien
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Publication number: 20170057172Abstract: A tool path generator with embedded process control commands enables feed-forward process control for additive manufacturing.Type: ApplicationFiled: August 23, 2016Publication date: March 2, 2017Inventors: David M. Keicher, Adam Cook
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Publication number: 20160129634Abstract: Hydrodynamic focusing of two fluid steams provides a novel micro printing technology for printed electronics and other high performance applications.Type: ApplicationFiled: November 5, 2015Publication date: May 12, 2016Inventors: David M. Keicher, Adam Cook
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Patent number: 7879394Abstract: 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: GrantFiled: June 1, 2007Date of Patent: February 1, 2011Assignee: Optomec, Inc.Inventors: David M. Keicher, Lucas B. Brewer, Richard John Grylls
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Patent number: 6811744Abstract: 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: GrantFiled: April 22, 2002Date of Patent: November 2, 2004Assignee: Optomec Design CompanyInventors: David M. Keicher, James W. Love, Kevin J. Dullea, James L. Bullen, Pierrette H. Gorman, Mark E. Smith
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Patent number: 6656409Abstract: 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: GrantFiled: July 7, 2000Date of Patent: December 2, 2003Assignee: Optomec Design CompanyInventors: David M. Keicher, James W. Love
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Publication number: 20030206820Abstract: 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: ApplicationFiled: April 22, 2002Publication date: November 6, 2003Inventors: David M. Keicher, James W. Love, Kevin J. Dullea, James L. Bullen, Pierrette H. Gorman, Mark E. Smith
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Publication number: 20020170890Abstract: 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: ApplicationFiled: April 27, 2001Publication date: November 21, 2002Inventors: David M. Keicher, W. Doyle Miller, Marcelino Essien
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Patent number: 6476343Abstract: 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: GrantFiled: April 24, 1998Date of Patent: November 5, 2002Assignee: Sandia CorporationInventors: 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
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Patent number: 6391251Abstract: 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: GrantFiled: May 9, 2000Date of Patent: May 21, 2002Assignee: Optomec Design CompanyInventors: David M. Keicher, James L. Bullen, Pierrette H. Gorman, James W. Love, Kevin J. Dullea, Mark E. Smith
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Publication number: 20020051853Abstract: 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: ApplicationFiled: April 24, 2001Publication date: May 2, 2002Inventors: David M. Keicher, W. Doyle Miller
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Patent number: 6268584Abstract: 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: GrantFiled: July 20, 1998Date of Patent: July 31, 2001Assignee: Optomec Design CompanyInventors: David M. Keicher, W. Doyle Miller
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Publication number: 20010008230Abstract: 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: ApplicationFiled: April 24, 1998Publication date: July 19, 2001Inventors: 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
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Patent number: 6251488Abstract: 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: GrantFiled: May 5, 1999Date of Patent: June 26, 2001Assignee: Optomec Design CompanyInventors: W. Doyle Miller, David M. Keicher, Marcelino Essien
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Patent number: 6075220Abstract: 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: GrantFiled: February 12, 1998Date of Patent: June 13, 2000Assignee: Sandia CorporationInventors: Marcelino Essien, David M. Keicher, M. Eric Schlienger, James L. Jellison
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Patent number: 6046426Abstract: 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: GrantFiled: July 8, 1996Date of Patent: April 4, 2000Assignee: Sandia CorporationInventors: Francisco P. Jeantette, David M. Keicher, Joseph A. Romero, Lee P. Schanwald