Patents by Inventor Scott McCarthy

Scott McCarthy 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: 12337529
    Abstract: A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a calibration plane used for a first spatial calibration, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets.
    Type: Grant
    Filed: May 15, 2023
    Date of Patent: June 24, 2025
    Assignee: General Electric Company
    Inventors: Brian Scott McCarthy, Dean Andrew Snelling, Jr., Thomas Adcock, Donnell Crear, Michael Evans Graham
  • Publication number: 20240342801
    Abstract: An additive manufacturing system and a method for manufacturing a solid component with the additive manufacturing system is provided. The method includes determining a misalignment vector field having a plurality of misalignment vectors. The method further includes identifying one or more potential stitching positions where the solid component is generally tangent to one or more misalignment vectors. The method further includes generating a plurality of first hatching paths, a plurality of second hatching paths, and one or more stitching regions. The method further includes selectively directing the first laser beam across a powder bed along the plurality of first hatching paths to consolidate a first portion of the solid component. The method further includes selectively directing the second laser beam across the powder bed along the plurality of second hatching paths to consolidate a second portion of the solid component.
    Type: Application
    Filed: April 17, 2023
    Publication date: October 17, 2024
    Inventors: Thomas Charles Adcock, Brian Scott McCarthy
  • Publication number: 20240326129
    Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component including a plurality of elements and at least one region of interest. The control system is also configured to apply at least one strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile based on the at least one strain load. The control system is further configured to determine a build parameter based at least partly on the build characteristic contribution profile.
    Type: Application
    Filed: June 10, 2024
    Publication date: October 3, 2024
    Inventors: Brian Scott McCarthy, Aymeric Moinet, Rajesh Kartik Bollapragada, Tyler Nathaniel Nelson
  • Patent number: 12103107
    Abstract: A method of aligning at least one laser beam of an additive manufacturing arrangement. The method includes measuring a surface of the calibration plate at a plurality of measurement points using the coordinate measuring machine. The method further includes generating a correction field based on the plurality of measurement points using the coordinate measuring machine. The method further includes writing at least one fiducial mark on the surface of the calibration plate using the at least one laser beam. The method further includes generating calibration data for the surface of the calibration plate using the calibration system. The method also includes aligning the laser beam within the additive manufacturing system based on the calibration data and the correction field using the computing device by comparing a position of the fiducial mark from the calibration data with the correction field to determine a corrected position of the laser beam.
    Type: Grant
    Filed: July 18, 2019
    Date of Patent: October 1, 2024
    Assignee: General Electric Company
    Inventors: Brian Scott McCarthy, Eric Edward Halla, Thomas Charles Adcock, Michael Evans Graham, Andrea Marie Schmitz, Mark Samuel Bailey
  • Patent number: 12017135
    Abstract: A wheel hub configured to be used with an electric vehicle. The wheel hub includes a hollow cylindrical body, a direct drive motor, a hollow axle, a battery, and a tire. The hollow cylindrical body includes a first end surface and a second end surface that is axially opposite and spaced apart from the first end surface. The direct drive motor is disposed within the hollow cylindrical body and is configured to rotate the cylindrical body about a central axis of the motor. The hollow axle has a central axis that is coaxial with the motor central axis and is at least partially disposed within the cylindrical body. The battery is disposed within the hollow cylindrical body and is in electrical communication with the direct drive motor. The tire is fixedly coupled and disposed on an external surface of the hollow cylindrical body.
    Type: Grant
    Filed: June 24, 2021
    Date of Patent: June 25, 2024
    Assignee: Milton, LLC
    Inventors: Scott McCarthy, Logan McCarthy
  • Patent number: 12005498
    Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component including a plurality of elements and at least one region of interest. The control system is also configured to apply at least one strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile based on the at least one strain load. The control system is further configured to determine a build parameter based at least partly on the build characteristic contribution profile.
    Type: Grant
    Filed: July 31, 2020
    Date of Patent: June 11, 2024
    Assignee: General Electric Company
    Inventors: Brian Scott McCarthy, Aymeric Moinet, Rajesh Kartik Bollapragada, Tyler Nathaniel Nelson
  • Publication number: 20240017481
    Abstract: Methods of additively manufacturing a three-dimensional object include irradiating a first build plane region using a first energy beam defining a beam diameter, the first energy beam travelling along a first oscillating path in a first direction to consolidate a first wall defining a thickness perpendicular to the first direction, wherein a build material adjacent a first side of the first wall and the build material adjacent a second side of the first wall, opposite the first side of the first wall, remains unconsolidated; and wherein the thickness of the first wall is greater than the beam diameter.
    Type: Application
    Filed: July 15, 2022
    Publication date: January 18, 2024
    Inventors: Victor Petrovich Ostroverkhov, Christopher Darby Immer, Thomas Charles Adcock, Justin John Gambone, Daniel Jason Erno, Brian Scott McCarthy, John Joseph Madelone, JR.
  • Publication number: 20230278282
    Abstract: A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a calibration plane used for a first spatial calibration, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets.
    Type: Application
    Filed: May 15, 2023
    Publication date: September 7, 2023
    Inventors: Brian Scott McCarthy, Dean Andrew Snelling, JR., Thomas Adcock, Donnell Crear, Michael Evans Graham
  • Patent number: 11679551
    Abstract: A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a reference plane containing the burn-paper when the fiducial marks were generated, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets.
    Type: Grant
    Filed: February 28, 2019
    Date of Patent: June 20, 2023
    Assignee: General Electric Company
    Inventors: Brian Scott McCarthy, Dean Andrew Snelling, Jr., Thomas Adcock, Donnell Crear, Michael Evans Graham
  • Patent number: 11555794
    Abstract: A method of identifying at least one pole location on a bearing element formed from a metal source element. The method is non-destructive and does not alter the surface of the bearing element. The method includes applying X-rays to a plurality of regions of a bearing element, and measuring diffracted intensity values of X-ray diffraction vectors or bi-sectors at the plurality of regions. The method includes determining at least one pole location on the bearing element based on the diffracted intensity values.
    Type: Grant
    Filed: December 1, 2021
    Date of Patent: January 17, 2023
    Assignee: Schaeffler Technologies AG & Co. KG
    Inventor: Scott McCarthy
  • Publication number: 20220409984
    Abstract: Various implementations include a wheel hub configured to be used with an electric vehicle. The wheel hub includes a hollow cylindrical body, a direct drive motor, a hollow axle, a battery, and a tire. The hollow cylindrical body includes a first end surface and a second end surface that is axially opposite and spaced apart from the first end surface. The direct drive motor is disposed within the hollow cylindrical body and is configured to rotate the cylindrical body about a central axis of the motor. The hollow axle has a central axis that is coaxial with the motor central axis and is at least partially disposed within the cylindrical body. The battery is disposed within the hollow cylindrical body and is in electrical communication with the direct drive motor. The tire is fixedly coupled and disposed on an external surface of the hollow cylindrical body.
    Type: Application
    Filed: June 24, 2021
    Publication date: December 29, 2022
    Inventors: Scott McCarthy, Logan McCarthy
  • Patent number: 11407170
    Abstract: An additive manufacturing system includes a first laser device configured to generate a first laser beam and a second laser device configured to generate a second laser beam. The laser scanning devices include a first laser scanning device and a second laser scanning device. The first laser scanning device is configured to selectively direct the first laser beam from the first laser devices across a powder bed along a plurality of first hatching paths and a first contour path along a contour of the solid component. The second laser scanning device is configured to selectively direct the second laser beam from the second laser devices across the powder bed along a plurality of second hatching paths and a second contour path along the contour of the solid component. The first contour path includes a first hook extending into the plurality of second hatching paths.
    Type: Grant
    Filed: December 20, 2019
    Date of Patent: August 9, 2022
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Brian Scott McCarthy, John Joseph Madelone, Jr., Justin John Gambone, Jr., Rachel Wyn Levine
  • Patent number: 11325020
    Abstract: Various implementations include a skateboard truck including a baseplate, a hanger, and a kingpin. The baseplate defines has a mounting surface. The hanger includes a main portion, a pivot pin, a first branch, and a second branch. The pivot pin is disposed within a pivot cup of the baseplate. The kingpin is disposed within openings in the baseplate and hanger. The branches each have curved longitudinal axes, a first portion coupled to the main portion, and a middle portion coupling the first and second portions. The second portion of each of the branches defines an axle opening. The first portion extends from the main portion toward the middle portion in a direction away from a mounting surface plane. The second portion extends from the middle portion in a direction toward the mounting surface plane. The first portions are closer to each other than the second portions are to each other.
    Type: Grant
    Filed: December 10, 2020
    Date of Patent: May 10, 2022
    Assignee: Milton, LLC
    Inventors: Scott McCarthy, Logan McCarthy
  • Publication number: 20220032549
    Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component. The model includes a plurality of elements and at least one region of interest. The control system is also configured to apply a strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile for at least one element of the plurality of elements. The build characteristic contribution profile represents an effect of the strain load applied to the at least one element on a build characteristic of at least one location within the at least one region of interest. The control system is further configured to adjust a build parameter for a location within the component relating to the at least one element of the plurality of elements based on the build characteristic contribution profile.
    Type: Application
    Filed: July 30, 2020
    Publication date: February 3, 2022
    Inventors: Brian Scott McCarthy, Aymeric Moinet, Evan John Dozier, Sathyanarayanan Raghavan, Michael Evans Graham, Tyler Nathaniel Nelson, Rajesh Kartik Bollapragada
  • Publication number: 20220032367
    Abstract: An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component including a plurality of elements and at least one region of interest. The control system is also configured to apply at least one strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile based on the at least one strain load. The control system is further configured to determine a build parameter based at least partly on the build characteristic contribution profile.
    Type: Application
    Filed: July 31, 2020
    Publication date: February 3, 2022
    Inventors: Brian Scott McCarthy, Aymeric Moinet, Rajesh Kartik Bollapragada, Tyler Nathaniel Nelson
  • Patent number: 11141818
    Abstract: 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: Grant
    Filed: February 5, 2018
    Date of Patent: October 12, 2021
    Assignee: General Electric Company
    Inventors: William Thomas Carter, Todd Jay Rockstroh, Brian Scott McCarthy, Subhrajit Roychowdhury, Younkoo Jeong, David Charles Bogdan, Jr.
  • Publication number: 20210187830
    Abstract: An additive manufacturing system includes a first laser device configured to generate a first laser beam and a second laser device configured to generate a second laser beam. The laser scanning devices include a first laser scanning device and a second laser scanning device. The first laser scanning device is configured to selectively direct the first laser beam from the first laser devices across a powder bed along a plurality of first hatching paths and a first contour path along a contour of the solid component. The second laser scanning device is configured to selectively direct the second laser beam from the second laser devices across the powder bed along a plurality of second hatching paths and a second contour path along the contour of the solid component. The first contour path includes a first hook extending into the plurality of second hatching paths.
    Type: Application
    Filed: December 20, 2019
    Publication date: June 24, 2021
    Inventors: Brian Scott McCarthy, John Joseph Madelone, JR., Justin John Gambone, JR., Rachel Wyn Levine
  • Publication number: 20210016394
    Abstract: A method of aligning at least one laser beam of an additive manufacturing arrangement. The method includes measuring a surface of the calibration plate at a plurality of measurement points using the coordinate measuring machine. The method further includes generating a correction field based on the plurality of measurement points using the coordinate measuring machine. The method further includes writing at least one fiducial mark on the surface of the calibration plate using the at least one laser beam. The method further includes generating calibration data for the surface of the calibration plate using the calibration system. The method also includes aligning the laser beam within the additive manufacturing system based on the calibration data and the correction field using the computing device by comparing a position of the fiducial mark from the calibration data with the correction field to determine a corrected position of the laser beam.
    Type: Application
    Filed: July 18, 2019
    Publication date: January 21, 2021
    Inventors: Brian Scott McCarthy, Eric Edward Halla, Thomas Charles Adcock, Michael Evans Graham, Andrea Marie Schmitz, Mark Samuel Bailey
  • Publication number: 20200172434
    Abstract: Methods and apparatuses for delivering and retaining solid chemicals in molten salt baths are provided, the chemicals may serve to reduce the lithium poisoning level of the molten salt bath. Methods and apparatuses are also provided for retaining sludge in a molten salt bath, allowing for removal of the sludge from the molten salt bath.
    Type: Application
    Filed: November 22, 2019
    Publication date: June 4, 2020
    Inventors: John Martin Dafin, Jeffrey Alan Decker, William Jason Hill, Yuhui Jin, James Paul McCann, Alan Scott McCarthy
  • Publication number: 20190240781
    Abstract: 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: Application
    Filed: February 5, 2018
    Publication date: August 8, 2019
    Inventors: William Thomas Carter, Todd Jay Rockstroh, Brian Scott McCarthy, Subhrajit Roychowdhury, Younkoo Jeong, David Charles Bogdan, JR.