Patents by Inventor Jason Harris Karp
Jason Harris Karp 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: 11931825Abstract: An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.Type: GrantFiled: November 21, 2022Date of Patent: March 19, 2024Assignee: General Electric CompanyInventors: Jason Harris Karp, Victor Petrovich Ostroverkhov
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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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Publication number: 20230083950Abstract: An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.Type: ApplicationFiled: November 21, 2022Publication date: March 16, 2023Applicant: General Electric CompanyInventors: Jason Harris Karp, Victor Petrovich Ostroverkhov
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Patent number: 11584083Abstract: A system and method including receiving a data model representation of a part, the data model representation including at least one layer of the part and inner and outer contours for the at least one layer; determining a hatch pattern for each layer of the at least one layer of the part, the hatch pattern for each layer being dependent on the inner and outer contours for each respective layer; generating a record of the determined hatch pattern for each layer, the record including locations for the hatch pattern for each layer; and saving the record of the determined hatch pattern for each layer of the part. In some aspects, the record of the determined hatch pattern for each layer of the part may be used in an additive manufacturing process.Type: GrantFiled: September 26, 2019Date of Patent: February 21, 2023Assignee: GENERAL ELECTRIC COMPANYInventors: David S. Toledano, Jason Harris Karp, William T. Carter
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Patent number: 11548094Abstract: An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.Type: GrantFiled: February 15, 2017Date of Patent: January 10, 2023Assignee: General Electric CompanyInventors: Jason Harris Karp, Victor Petrovich Ostroverkhov
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Publication number: 20220305726Abstract: A system for use in additively manufacturing an object. The system includes a powder bed configured for containment within a build chamber, wherein the powder bed is formed from a mixture of a build material and a bonding agent. The system also includes a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent. The heat source also selectively heats the powder bed to the temperature that maintains the build material in a solid state.Type: ApplicationFiled: June 14, 2022Publication date: September 29, 2022Inventors: Scott Michael Oppenheimer, Richard DiDomizio, Jason Harris Karp
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Patent number: 11364679Abstract: A system for use in additively manufacturing an object. The system includes a powder bed configured for containment within a build chamber, wherein the powder bed is formed from a mixture of a build material and a bonding agent. The system also includes a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent. The heat source also selectively heats the powder bed to the temperature that maintains the build material in a solid state.Type: GrantFiled: November 1, 2019Date of Patent: June 21, 2022Assignee: General Electric CompanyInventors: Scott Michael Oppenheimer, Richard DiDomizio, Jason Harris Karp
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Patent number: 11287408Abstract: A gas detector sensor node includes a first sensor conductor having a terminal end, a second sensor conductor including an end section, and a coupler joining the terminal end of the first sensor conductor with the end section of the second sensor conductor. The coupler is permeable to gas.Type: GrantFiled: April 30, 2019Date of Patent: March 29, 2022Assignee: BAKER HUGHES, A GE COMPANY, LLCInventors: Jason Harris Karp, William Albert Challener
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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: 11161201Abstract: A powder melting device for an additive manufacturing system is provided. The powder melting device includes at least one laser device configured to generate at least one energy beam for forming at least one melt pool in a layer of powdered material. The powder melting device also includes at least two optical elements configured to dynamically induce beam distortion in the at least one energy beam to modify a beam spot incident on the layer of powdered material. The at least two optical elements are configured to induce at least one of an aspect ratio adjustment of the at least one energy beam, an optical powder redistribution between a periphery and a center of the at least one energy beam, and a rotation of the at least one energy beam.Type: GrantFiled: May 31, 2017Date of Patent: November 2, 2021Assignee: General Electric CompanyInventors: Victor Petrovich Ostroverkhov, Jason Harris Karp, Mark Marshall Meyers, William Thomas Carter
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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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Publication number: 20210129427Abstract: A system for use in additively manufacturing an object. The system includes a powder bed configured for containment within a build chamber, wherein the powder bed is formed from a mixture of a build material and a bonding agent. The system also includes a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent. The heat source also selectively heats the powder bed to the temperature that maintains the build material in a solid state.Type: ApplicationFiled: November 1, 2019Publication date: May 6, 2021Inventors: Scott Michael Oppenheimer, Richard DiDomizio, Jason Harris Karp
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Publication number: 20210094235Abstract: A system and method including receiving a data model representation of a part, the data model representation including at least one layer of the part and inner and outer contours for the at least one layer; determining a hatch pattern for each layer of the at least one layer of the part, the hatch pattern for each layer being dependent on the inner and outer contours for each respective layer; generating a record of the determined hatch pattern for each layer, the record including locations for the hatch pattern for each layer; and saving the record of the determined hatch pattern for each layer of the part. In some aspects, the record of the determined hatch pattern for each layer of the part may be used in an additive manufacturing process.Type: ApplicationFiled: September 26, 2019Publication date: April 1, 2021Inventors: David S. Toledano, Jason Harris Karp, William T. Carter
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Patent number: 10960607Abstract: An additive manufacturing system is configured to manufacture a component. The additive manufacturing system includes a build platform, a recoater, a monitoring camera, and a controller. The component is disposed on the build platform. The recoater includes a recoater blade configured to spread a powdered build material across the build platform and the component forming a powder bed. The monitoring camera is positioned to image the recoater blade. The monitoring camera is configured to acquire a plurality of images of the recoater blade. The controller is configured to receive the plurality of images from the monitoring camera. The controller is configured to detect defects in the powder bed based on the plurality of images received from the monitoring camera.Type: GrantFiled: December 13, 2018Date of Patent: March 30, 2021Assignee: General Electric CompanyInventors: Victor Petrovich Ostroverkhov, Jason Harris Karp
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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: 10814427Abstract: An additive manufacturing system includes a laser device, a build plate, a first scanning device, and an alignment system. The laser device is configured to generate a laser beam. The build plate has a position relative to the laser device. The first scanning device is configured to selectively direct the laser beam across the build plate. The laser beam generates a melt pool on the build plate. The alignment system includes a fiducial marks projector configured to project a plurality of fiducial marks across the build plate. Each fiducial mark has a location on the build plate. The alignment system also includes an optical detector configured to detect the location of each of the fiducial marks on the build plate. The alignment system is configured to detect the position of the build plate relative to the laser device.Type: GrantFiled: January 10, 2018Date of Patent: October 27, 2020Assignee: General Electric CompanyInventors: Victor Petrovich Ostroverkhov, Harry Kirk Mathews, Jr., Justin John Gambone, Jr., Jason Harris Karp, Kevin George Harding, Scott Michael Miller, William Thomas Carter
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Patent number: 10816458Abstract: A gas analysis system includes spectroscopy assembly coupled to a vehicle. The spectroscopy assembly includes a plurality of emitters configured to emit a plurality of light beams toward a target surface. Each light beam of the plurality of light beams comprises a predetermined wavelength. The spectroscopy assembly includes a collection optic configured to receive a plurality of reflected light beams reflected from the target surface. Additionally, the spectroscopy assembly includes a detector configured to receive the plurality of reflected light beams from the collection optic and to detect a spectral intensity of the plurality of reflected light beams. Further, the spectroscopy assembly includes a controller configured to receive a light beam signal from the detector indicative of the spectral intensity of the plurality of reflected light beams. The controller is configured to detect a target fluid based on the light beam signal.Type: GrantFiled: December 10, 2018Date of Patent: October 27, 2020Assignee: GENERAL ELECTRIC COMPANYInventors: Ansas Matthias Kasten, William Albert Challener, Jason Harris Karp, Cheng-Po Chen
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Patent number: 10766242Abstract: A consolidating device for an additive manufacturing system is provided. The consolidating device includes at least one first energy beam generator, at least one second energy beam generator, at least one first lens, at least one second lens, and at least one reflective element. The first energy beam generator is configured to generate a first energy beam. The second energy beam generator is configured to generate a second energy beam. The first lens has a first entrance pupil and is positioned between the first energy beam generator and the layer of material. The second lens has a second entrance pupil and is positioned between the first lens and the layer of material. The first entrance pupil and the second entrance pupil substantially overlap. The reflective element is positioned between the first lens and the second lens, and is configured to reflect the second energy beam onto the layer of material.Type: GrantFiled: August 24, 2017Date of Patent: September 8, 2020Assignee: General Electric CompanyInventors: Jason Harris Karp, Victor Petrovich Ostroverkhov
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Publication number: 20200189193Abstract: An additive manufacturing system is configured to manufacture a component. The additive manufacturing system includes a build platform, a recoater, a monitoring camera, and a controller. The component is disposed on the build platform. The recoater includes a recoater blade configured to spread a powdered build material across the build platform and the component forming a powder bed. The monitoring camera is positioned to image the recoater blade. The monitoring camera is configured to acquire a plurality of images of the recoater blade. The controller is configured to receive the plurality of images from the monitoring camera. The controller is configured to detect defects in the powder bed based on the plurality of images received from the monitoring camera.Type: ApplicationFiled: December 13, 2018Publication date: June 18, 2020Inventors: Victor Petrovich Ostroverkhov, Jason Harris Karp
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Publication number: 20200182779Abstract: A gas analysis system includes spectroscopy assembly coupled to a vehicle. The spectroscopy assembly includes a plurality of emitters configured to emit a plurality of light beams toward a target surface. Each light beam of the plurality of light beams comprises a predetermined wavelength. The spectroscopy assembly includes a collection optic configured to receive a plurality of reflected light beams reflected from the target surface. Additionally, the spectroscopy assembly includes a detector configured to receive the plurality of reflected light beams from the collection optic and to detect a spectral intensity of the plurality of reflected light beams. Further, the spectroscopy assembly includes a controller configured to receive a light beam signal from the detector indicative of the spectral intensity of the plurality of reflected light beams. The controller is configured to detect a target fluid based on the light beam signal.Type: ApplicationFiled: December 10, 2018Publication date: June 11, 2020Inventors: Ansas Matthias Kasten, William Albert Challener, Jason Harris Karp, Cheng-Po Chen