Patents by Inventor Donnell Eugene Crear

Donnell Eugene Crear 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).

  • Publication number: 20180361502
    Abstract: A component includes a body, and an interface in the body defining a first and second portion of the body made by different melting beam sources of a multiple melting beam source additive manufacturing system during a single build. The component also includes a channel extending through the body. The channel includes an interface-distant area on opposing sides of the interface, each interface-distant area having a first width. The channel also includes an enlarged width area fluidly communicative with the interface-distant areas and spanning the interface, the enlarged width area having a second width larger than the first width. Any misalignment of the melting beams at the interface is addressed by the enlarged width area, eliminating the problem of reduced cooling fluid flow in the channel.
    Type: Application
    Filed: June 19, 2017
    Publication date: December 20, 2018
    Inventors: Felix Martin Gerhard Roerig, Donnell Eugene Crear, Juan Vicente Haro Gonzalez, Mikhail Pavlov, Dean Andrew Snelling, JR.
  • Publication number: 20180356350
    Abstract: A damaged applicator identifier system for an additive manufacturing (AM) system, and AM system including the same are disclosed. The damaged applicator identifier system may include a damaged applicator identifier determining whether the active applicator is damaged by identifying a non-planar surface in a layer of raw material on a build platform of the AM system after formation of the layer by the active applicator. A damaged applicator controller is configured to cause replacement or repair of the damaged, active applicator in response to the damaged applicator identifier identifying the damaged, active applicator.
    Type: Application
    Filed: June 12, 2017
    Publication date: December 13, 2018
    Inventors: Donnell Eugene Crear, Tiffany Muller Craft, Kassy Moy Hart, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling
  • Publication number: 20180354208
    Abstract: An applicator repair system for an additive manufacturing (AM) system, and an AM system including the same are disclosed. The applicator repair system includes a repair device including a repair element configured to repair a damaged applicator element on an applicator of an AM system. The damaged applicator element is configured to distribute a layer of raw material on a build platform of the AM system. The repair device is positioned within a processing chamber of the AM system. A damaged applicator controller may be provided that is configured to cause repair of the damaged active applicator in response to the damaged applicator being identified as damaged.
    Type: Application
    Filed: June 12, 2017
    Publication date: December 13, 2018
    Inventors: Donnell Eugene Crear, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling
  • Publication number: 20180348367
    Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a build plate positioned directly on a movable build platform, and a recoater device positioned above the build plate. The recoater device may include a blade. Additionally, the AMS may include a calibration system operably connected to the recoater device. The calibration system may include at least one measurement device coupled or positioned adjacent to the recoater device, and at least one computing device operably connected to the measurement device(s). The computing device(s) may be configured to calibrate the recoater device by adjusting a height of the blade of the recoater device relative to a reference surface of a component of the AMS in response to determining a pre-build distance between the blade of the recoater device and the reference surface differs from a desired distance. The pre-build distance may be determined using the measurement device(s).
    Type: Application
    Filed: May 30, 2017
    Publication date: December 6, 2018
    Inventors: Donnell Eugene Crear, Mikhail Pavlov, Felix Martin Gerhard Roerig, Dean Andrew Snelling, JR.
  • Publication number: 20180348492
    Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a movable build platform, and a calibration system operably connected to the build platform. The calibration system may include a reflective element operably coupled to the build platform, a first calibration model positioned above and vertically offset from the reflective element, and a first camera substantially aligned with the first calibration model. The first camera may be visually aligned with the reflective element to capture a first reflective image of the first calibration model as reflected by the reflective element. The calibration system may also include at least one computing device operably connected to the build platform and the first camera, and configured to calibrate the build platform by: adjusting an actual inclination of the build platform in response to determining the first reflective image differs from a predetermined image of the first calibration model.
    Type: Application
    Filed: May 30, 2017
    Publication date: December 6, 2018
    Inventors: Mikhail Pavlov, Donnell Eugene Crear, Felix Martin Gerhard Roerig, Dean Andrew Snelling, JR.
  • Publication number: 20180347969
    Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a build platform, and energy emitting device(s) positioned above the build platform. Energy emitting device(s) may be configured to form a test mark directly on a reference surface of the AMS. AMS may also include a calibration system operably connected to the energy emitting device(s). The calibration system may include measurement device(s) configured to determine an actual location of the test mark on the reference surface, and computing device(s) operably connected to the energy emitting device(s) and the measurement device(s). The computing device(s) may be configured to calibrate the energy emitting device(s) by adjusting the energy emitting device(s) in response to determining the actual location of the test mark on the reference surface from a predetermined, desired location on the reference surface.
    Type: Application
    Filed: May 30, 2017
    Publication date: December 6, 2018
    Inventors: Dean Andrew Snelling, JR., Donnell Eugene Crear, Mikhail Pavlov, Felix Martin Gerhard Roerig
  • Patent number: 10112260
    Abstract: Methods for aligning a pair of calibrated lasers of a laser additive manufacturing system in an overlap region in which the pair of calibrated lasers selectively operate are provided. Respective first and second plurality of layers of a test structure are formed in the overlap region of the pair of calibrated lasers solely using a first calibrated laser of the pair of calibrated lasers and then solely using a second calibrated laser of the pair of calibrated lasers. The test structure forming creates an outer surface of the test structure corresponding to the overlap region. A dimension(s) of an offset step(s) created between the first plurality of layers and the second plurality of lasers in the outer surface of the test structure is/are measured. The lasers are aligned by applying the dimension(s) of the offset step(s) as an alignment correction(s) to at least one of the pair of calibrated lasers.
    Type: Grant
    Filed: January 20, 2016
    Date of Patent: October 30, 2018
    Assignee: General Electric Company
    Inventors: Donnell Eugene Crear, David Edward Schick, Archie Lee Swanner, Jr.
  • Publication number: 20180299359
    Abstract: A test feature is disclosed that is formed during metal powder additive manufacturing of a production part. The test feature may include a metal powder sample capsule including a chamber for capturing unfused powder from the metal powder additive manufacturing, and a removable cap closing an end of the chamber. Alternatively, a test feature may include a quality control (QC) part, and at least one additional test element including a metal powder sample capsule integrally coupled to the QC part and including a chamber for capturing unfused powder from the metal powder additive manufacturing. The QC part is identical to the production part excepting the at least one test element. The QC part and the at least one test element are formed during the same metal powder additive manufacturing as the production part.
    Type: Application
    Filed: April 18, 2017
    Publication date: October 18, 2018
    Inventors: Jose Troitino Lopez, Tiffany Muller Craft, Donnell Eugene Crear, Kassy Moy Hart, Kamilla Koenig-Urban, Eric Eicher McConnell, Danijel Medved
  • Patent number: 10054530
    Abstract: Particle detection systems are disclosed. The particle detection system may include a conduit configured to receive particles removed from a component, and at least one sensor positioned adjacent the conduit. The at least one sensor may be configured to detect a particle characteristic for the particles in the conduit removed from the component. The particle detection system may also include a particle analysis system in communication with the at least one sensor. The particle analysis system may be configured to analyze the particle characteristic for the particles in the conduit to determine if the component is substantially free of particles.
    Type: Grant
    Filed: August 16, 2016
    Date of Patent: August 21, 2018
    Assignee: General Electric Company
    Inventors: Archie Lee Swanner, Jr., Tiffany Muller Craft, Donnell Eugene Crear, Chad Joseph Dulkiewicz, Kassy Moy Hart
  • Publication number: 20180207889
    Abstract: Embodiments of the present disclosure relate to a material extraction tool, including: a body shaped to sealingly engage an aperture in a component, the aperture defining a fluid connection between a hollow interior of the component and an exterior of the component; a first passage within the body, the first passage fluidly connecting the hollow interior of the component to an air conduit outside the body, the air conduit fluidly coupled to a compressed air supply; and a second passage within the body, the second passage fluidly connecting the hollow interior of the component to an extraction conduit outside the body, the extraction conduit fluidly coupled to a material repository positioned outside the hollow interior of the component.
    Type: Application
    Filed: January 24, 2017
    Publication date: July 26, 2018
    Inventors: Archie Lee Swanner, JR., Tiffany Muller Craft, Donnell Eugene Crear, Kassy Moy Hart, Tony Lee Stedge
  • Patent number: 9993873
    Abstract: A system and method for three-dimensional printing are provided. One three-dimensional printing system includes a first printing surface configured to hold a first three-dimensional object. The three-dimensional printing system also includes a second printing surface configured to hold a second three-dimensional object. The three-dimensional printing system includes at least one printing head disposed adjacent to the first and second printing surfaces for printing the first and second three-dimensional objects. A vertical position of the first printing surface is controlled independently from a vertical position of the second printing surface.
    Type: Grant
    Filed: May 22, 2012
    Date of Patent: June 12, 2018
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Michael Andrew Kovalcik, Eric Alan Estill, Donnell Eugene Crear
  • Publication number: 20180099458
    Abstract: A powder-filling apparatus includes a rolling frame, a powder hopper, and a powder-transferring apparatus. The rolling frame includes a support base and a lifting element coupled to the support base, the lifting element having a portion linearly movable toward and away from the support base. The powder hopper is mounted on the lifting element and adjustable in height with adjustment of the lifting element to achieve filling positions over a plurality of differently sized additive manufacturing printers. The powder-transferring apparatus is coupled with the powder hopper and is configured to transfer additive manufacturing powder from an additive manufacturing powder container to the powder hopper.
    Type: Application
    Filed: October 6, 2016
    Publication date: April 12, 2018
    Inventors: Donnell Eugene Crear, Archie Lee Swanner, JR.
  • Publication number: 20180071821
    Abstract: Various aspects include systems and methods for analyzing materials in additive manufacturing processes. In some cases, a system includes: an additive manufacturing (AM) printer for printing an AM object, the AM printer including a raw material chamber and a build chamber; a control system coupled with the AM printer configured to control the printing of the AM object; and a material analysis system coupled with the control system and the AM printer, the material analysis system configured to analyze a raw material obtained directly from at least one of the raw material chamber or the build chamber for a defect prior to, or contemporaneously with, additively manufacturing the AM component.
    Type: Application
    Filed: September 13, 2016
    Publication date: March 15, 2018
    Inventors: Donnell Eugene Crear, Ray Joshua Bohon, Steven Charles Woods
  • Publication number: 20180052087
    Abstract: Particle detection systems are disclosed. The particle detection system may include a conduit configured to receive particles removed from a component, and at least one sensor positioned adjacent the conduit. The at least one sensor may be configured to detect a particle characteristic for the particles in the conduit removed from the component. The particle detection system may also include a particle analysis system in communication with the at least one sensor. The particle analysis system may be configured to analyze the particle characteristic for the particles in the conduit to determine if the component is substantially free of particles.
    Type: Application
    Filed: August 16, 2016
    Publication date: February 22, 2018
    Inventors: Archie Lee Swanner, JR., Tiffany Muller Craft, Donnell Eugene Crear, Chad Joseph Dulkiewicz, Kassy Moy Hart
  • Publication number: 20180022044
    Abstract: Additive manufacturing systems are disclosed. The systems may include a base, and a retaining plate coupled to the base. The retaining plate may include a seat formed in an exposed surface of the retaining plate, and a plurality of pads extending laterally into the seat. The additive manufacturing systems may also include a build plate positioned within the seat and contacting the plurality of pads of the retaining plate. The build plate may include a build surface in substantial planar alignment with the exposed surface of the retaining plate. Additionally, the additive manufacturing systems may include a plurality of build plate retention components positioned in the seat of the retaining plate. Each of the plurality of build plate retention components may be utilized to retain the build plate within the seat of the retaining plate.
    Type: Application
    Filed: July 19, 2016
    Publication date: January 25, 2018
    Inventors: Chad Joseph Dulkiewicz, Donnell Eugene Crear
  • Publication number: 20180009007
    Abstract: Various embodiments of the invention include an apparatus for removing particulates from the surface of a 3D printed workpiece. Various particular embodiments include a material removal apparatus having: an enclosure having a first inlet and a first outlet; a rotatable platform contained within the enclosure for positioning a 3D printed workpiece having particulate on a surface thereof; a pressurized fluid applicator connected to the first inlet and configured to selectively apply a pressurized fluid to the 3D printed workpiece; a vibration source configured to apply an adjustable vibratory frequency to at least one of the rotatable platform or the 3D printed workpiece; and a material reclamation unit connected to the first outlet configured to collect a material removed from the 3D printed workpiece.
    Type: Application
    Filed: July 8, 2016
    Publication date: January 11, 2018
    Inventors: Tiffany Muller Craft, Donnell Eugene Crear, Kassy Moy Hart, Archie Lee Swanner, JR.
  • Patent number: 9821543
    Abstract: An additive manufacturing powder handling system includes a powder container and at least two of: an overflow powder collector system configured to collect overflow additive manufacturing powder from the additive manufacturing printer and pass the overflow additive manufacturing powder into the powder container; a vacuum system configured to receive by vacuum force additive manufacturing powder from an additive manufacturing printer and pass the additive manufacturing powder into the powder container; a sieve system configured to filter the additive manufacturing powder; and a powder container moving apparatus configured to move the powder container between any two of the additive manufacturing printer, the overflow powder collector system, the vacuum system, and the sieve system. The powder container includes a powder container coupling.
    Type: Grant
    Filed: October 7, 2016
    Date of Patent: November 21, 2017
    Assignee: General Electric Company
    Inventors: Donnell Eugene Crear, Archie Lee Swanner, Jr.
  • Publication number: 20170232552
    Abstract: A reclamation system for a metal powder, such as a reactive metal powder, is disclosed. The system may include a container; and a pressure source in fluid communication with the container for creating a selected pressure within the container, the container including: an inlet to a lower portion of the tank that is configured to hold a liquid, and an outlet. A controller controls the pressure source to control the pressure applied within the container between: a vacuum state creating a flow of air entrained metal powder to enter the inlet for forming a reclaimed metal powder by removing the metal powder from the air by immersion in the liquid, and an evaporation state that causes evaporation of the liquid to a gas that exits through the outlet. A condenser condenses the gas to a condensed liquid.
    Type: Application
    Filed: February 12, 2016
    Publication date: August 17, 2017
    Inventors: Donnell Eugene Crear, Archie Lee Swanner, JR.
  • Publication number: 20170203517
    Abstract: Methods for aligning a pair of calibrated lasers of a laser additive manufacturing system in an overlap region in which the pair of calibrated lasers selectively operate are provided. Respective first and second plurality of layers of a test structure are formed in the overlap region of the pair of calibrated lasers solely using a first calibrated laser of the pair of calibrated lasers and then solely using a second calibrated laser of the pair of calibrated lasers. The test structure forming creates an outer surface of the test structure corresponding to the overlap region. A dimension(s) of an offset step(s) created between the first plurality of layers and the second plurality of lasers in the outer surface of the test structure is/are measured. The lasers are aligned by applying the dimension(s) of the offset step(s) as an alignment correction(s) to at least one of the pair of calibrated lasers.
    Type: Application
    Filed: January 20, 2016
    Publication date: July 20, 2017
    Inventors: Donnell Eugene Crear, David Edward Schick, Archie Lee Swanner, JR.
  • Publication number: 20170182598
    Abstract: A metal powder additive manufacturing system and method are disclosed that use increased trace amounts of oxygen to improve physical attributes of an object. The system may include: a processing chamber; a metal powder bed within the processing chamber; a melting element configured to sequentially melt layers of metal powder on the metal powder bed to generate an object; and a control system configured to control a flow of a gas mixture within the processing chamber from a source of inert gas and a source of an oxygen containing material, the gas mixture including the inert gas and oxygen from the oxygen containing material.
    Type: Application
    Filed: December 28, 2015
    Publication date: June 29, 2017
    Inventors: Donnell Eugene Crear, Chad Joseph Dulkiewicz, Archie Lee Swanner, JR.