Using Laser Sintering Of Particulate Material To Build Three-dimensional Product (e.g., Sls, Selective Laser Sintering, Etc.) Patents (Class 264/497)
  • Patent number: 11911964
    Abstract: A method and an apparatus for collecting a powdered material after a print job in powder bed fusion additive manufacturing may involve a build platform supporting a powder bed capable of tilting, inverting, and shaking to separate the powder bed substantially from the build platform in a hopper. The powdered material may be collected in a hopper for reuse in later print jobs. The powder collecting process may be automated to increase efficiency of powder bed fusion additive manufacturing.
    Type: Grant
    Filed: October 28, 2016
    Date of Patent: February 27, 2024
    Assignee: Seurat Technologies, Inc.
    Inventors: James A. DeMuth, Erik Toomre, Francis L. Leard, Kourosh Kamshad, Heiner Fees, Eugene Berdichevsky
  • Patent number: 11904508
    Abstract: Simulated anatomical components, such as simulated vascular vessels, produced by a method that includes forming an anatomical component mold from a soluble polymer such that the mold defines an interior void of the simulated anatomical component. One or more layers of an elastomeric material is applied around the anatomical component mold and the material is allowed to cure to form a wall of the simulated anatomical component. At least a portion of the mold is dissolved to form a passage for liquid within the simulated anatomical component. Simulated anatomical components are connectable to other components of a surgical simulation system and can be modularized.
    Type: Grant
    Filed: November 1, 2020
    Date of Patent: February 20, 2024
    Assignee: ReSuture, Inc.
    Inventors: Hannah A. Eherenfeldt, Benjamin M. Knapp
  • Patent number: 11858169
    Abstract: The present invention relates to a method for producing shaped bodies (5) from a building material, in which a layered structure of a shaped body (5) takes place by successively solidifying layers of the building material by exposure to electromagnetic radiation in a layer area having a contour specified for the respective layer. The method provides that together with the shaped body (5), a sleeve-like frame (6) surrounding the shaped body at a distance is constructed layer by layer from the building material, and that in addition, a plurality of pin-like connections (10) are constructed integral with the frame (6) and the shaped body (5), which are distributed around the shaped body (5) and which connect the shaped body (5) with the frame (6).
    Type: Grant
    Filed: November 11, 2019
    Date of Patent: January 2, 2024
    Assignees: Ivoclar Vivadent AG, Technische Universität Wien
    Inventors: Jörg Ebert, Julia Anna Schönherr, Robert Gmeiner
  • Patent number: 11814539
    Abstract: A cross-linkable powder for use in a selective laser sintering (SLS) process for additive manufacturing is disclosed as well as a novel manufacturing process to form a 3D object using said cross-linkable powder. The manufacturing process makes it possible to create interlayer covalent bondings between deposited layers of cross-linkable powder such that 3D printed objects are achieved having improved mechanical strength, less object deformation and/or no warping.
    Type: Grant
    Filed: December 19, 2019
    Date of Patent: November 14, 2023
    Inventors: Hugo Verbeke, Bram Vanroy, David Briers
  • Patent number: 11745266
    Abstract: An example method for additive manufacturing of metals includes spreading a build material including a metal in a sequence of layers. Each layer has a respective thickness, a respective sequence position, and a respective exposed surface to receive energy from a flood energy source prior to spreading of a subsequent layer. Each respective exposed surface has a surface area of at least 5 square centimeters (cm2). Layer-by-layer, the exposed surface of each layer is exposed to the radiated energy from the flood energy source. The energy is radiated at an intensity profile and a fluence sufficient to cause a consolidating transformation of the build material in the exposed layer.
    Type: Grant
    Filed: April 30, 2018
    Date of Patent: September 5, 2023
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Seongsik Chang, Krzysztof Nauka
  • Patent number: 11731355
    Abstract: A system and method for autonomously creating subsequent physical objects using a 3-dimensional printer. The system includes a build platform which is ejected with a printed object adhered to it, with a replenishing mechanism to place a blank build platform into the expected build area such that printing a subsequent object may occur autonomously. The replenishing mechanism may draw from a plurality of stored blank build platforms which may be reusable in some embodiments and disposable in others.
    Type: Grant
    Filed: December 20, 2021
    Date of Patent: August 22, 2023
    Assignee: R3 Printing, Inc.
    Inventor: Paul Sieradzki
  • Patent number: 11724457
    Abstract: Methods and apparatus for forming a three-dimensional article in which a powdered medium is distributed in a powder bed, heated to a temperature below its melting point, and fused by means of a laser beam projected in the form of an image of a cross section of the three-dimensional article. The image of the cross-sectional layer is created by spatial light modulation of the laser beam using an LCoS display. During the fabrication process, characteristics of the image of the cross-sectional layer are controlled through monitoring of the projection of a holographic representation of the image using one or more imaging devices.
    Type: Grant
    Filed: May 27, 2021
    Date of Patent: August 15, 2023
    Inventors: Tomasz P. Cieszyński, Jakub Graczyk, Avi N. Reichental
  • Patent number: 11702559
    Abstract: In one aspect, inks for use with a three-dimensional (3D) printing system are described herein. In some embodiments, an ink described herein comprises up to 80 wt. % oligomeric curable material; up to 80 wt. % monomeric curable material; up to 10 wt. % photoinitiator; up to 1 wt. % non-curable absorber material; and up to 10 wt. % one or more additional components, based on the total weight of the ink, and wherein the total amount of the foregoing components is equal to 100 wt. %. Additionally, the photoinitiator is operable to initiate curing of the oligomeric curable material and/or the monomeric curable material when the photoinitiator is exposed to incident curing radiation having a peak wavelength ?. Moreover, the ink has a penetration depth (Dp), a critical energy (Ec), and a print through depth (DPT) at the wavelength ? of less than or equal to 2×Dp.
    Type: Grant
    Filed: June 3, 2022
    Date of Patent: July 18, 2023
    Assignee: 3D SYSTEMS, INC.
    Inventor: Khalil Moussa
  • Patent number: 11691342
    Abstract: A powder bed fusion apparatus for building an object in a layer-by-layer manner includes a build platform movable within a build sleeve to define a build volume, a layer formation device for forming layers of powder across the build volume in a working plane and an irradiation device for irradiating powder in the working plane to selectively fuse the powder. The powder bed fusion apparatus further includes a mechanical manipulator arranged to engage with the object and/or a build substrate, to which the object is attached, to tilt the object in a raised position above the working plane such that powder is freed from the object and deposited at a location above the working plane and/or into the build volume.
    Type: Grant
    Filed: August 20, 2021
    Date of Patent: July 4, 2023
    Assignee: RENISHAW PLC
    Inventors: David Roberts McMurtry, Christopher John Sutcliffe, Robin Geoffrey Weston, Paul Campton, David John Whitton, David Beeby
  • Patent number: 11648735
    Abstract: Arrangement (10) for the powder-bed-based additive manufacturing of a component (100), wherein the arrangement (10) comprises the following: a housing (12), which comprises a building volume (14), wherein the building volume (14) comprises a building area (16); at least three marker devices (20), which are fastened in or on the housing (12), wherein each marker device (20) is suitable for projecting a light reference marking (22) onto a component (100) lying on the building area (16) and/or onto the building area (16); a laser device (30) for the laser processing of a powder bed for generating a component (100) on the building area (16) by means of additive manufacturing, wherein the laser device (30) is set up for the laser processing of an associated working area (32a-32d), wherein the laser device (30) comprises a detection device (34), which is set up to sense the light reference markings (22); and a control unit (40), which is set up to calibrate the laser device (30) on the basis of the light reference
    Type: Grant
    Filed: June 26, 2018
    Date of Patent: May 16, 2023
    Assignee: RAYLASE GmbH
    Inventor: Wolfgang Lehmann
  • Patent number: 11642845
    Abstract: A three-dimensional printer for manufacturing additive printed parts includes a housing defining a cavity and first and second fixed rails extending along a first axis. First and second movable rails extend along a second axis and move independent of other another along the first axis. First and second print heads move along the second axis on the first and second movable rails, respectively, and first, second, and third dividers collectively separate the cavity to partially define process and instrument chambers. The first divider is mounted to the housing and the first movable rail and expands and contracts with the movement of the first movable rail. The second divider is mounted to the housing and the second movable rail and expands and contracts with the movement of the second movable rail. The third divider is mounted to the movable rails and expands and contracts with the movement of the movable rails.
    Type: Grant
    Filed: April 27, 2021
    Date of Patent: May 9, 2023
    Inventors: Yasushi Mizuno, Alex Stockton
  • Patent number: 11623389
    Abstract: The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.
    Type: Grant
    Filed: April 20, 2018
    Date of Patent: April 11, 2023
    Assignee: Desktop Metal, Inc.
    Inventors: Jonah Myerberg, Ricardo Fulop, Brett Schuster, Emanuel Michael Sachs, Paul A. Hoisington, Anastasios John Hart, Keith Vaillancourt, Steven Garrant, George Hudelson
  • Patent number: 11618212
    Abstract: According to some aspects, techniques are provided for fabricating sinterable metallic parts through the application of directed energy to a build material. In particular, applying energy to a build material comprising a polymer mixed with a metal powder may cause the polymer to form a cohesive structure with the metal powder. As a result, the polymer acts as a “glue” to produce a metallic green part without local melting of the metal. The green part may subsequently be sintered to remove the polymer and produce a fully dense metal part. Optionally, a step of debinding may also be performed prior to, or simultaneously with, sintering.
    Type: Grant
    Filed: March 20, 2020
    Date of Patent: April 4, 2023
    Assignee: Desktop Metal, Inc.
    Inventors: Jonah Samuel Myerberg, Anastasios John Hart
  • Patent number: 11571743
    Abstract: In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.
    Type: Grant
    Filed: November 13, 2017
    Date of Patent: February 7, 2023
    Assignee: General Electric Company
    Inventors: Michael Evans Graham, William Monaghan, Thomas Charles Adcock, Andrew J. Martin, John Joseph Madelone, Jr., David Charles Bogdan, Jr., John Broddus Deaton, Jr., William Thomas Carter
  • Patent number: 11559940
    Abstract: An interchangeable chamber is provided for a 3D printing device, wherein the interchangeable chamber includes a building space for receiving a building platform on which a three-dimensional object can be produced, which building space is designed to be temporarily open in the direction of a top of the interchangeable chamber, as well as optionally a storage container for storing building material and wherein the interchangeable chamber comprises a side wall and a cover, wherein the cover is adapted to close the interchangeable chamber at the top such that building material cannot get through the cover out of nor into the interchangeable chamber and the cover is coupled with the side wall.
    Type: Grant
    Filed: May 4, 2017
    Date of Patent: January 24, 2023
    Assignee: EOS GmBH Electro Optical Systems
    Inventors: Sven Pawliczek, Horst Maier, Robert Eichner, Alexander Krüger
  • Patent number: 11493650
    Abstract: A method for detecting a position of an energy beam comprises mapping a first density modulated x-ray signal with a plurality of locations on an energy beam target, thereby generating a model of a background x-ray intensity. The method further comprises forming an x-ray signal time series using subsequent intensity modulated x-ray signals, each resulting from scanning the energy beam along the energy beam target in one of a plurality of directions at one of a plurality of speeds, and determining the position of the energy beam based upon a received x-ray signal strength based on the x-ray signal time series and the model of the background x-ray intensity.
    Type: Grant
    Filed: May 11, 2020
    Date of Patent: November 8, 2022
    Assignee: Arcam AB
    Inventor: David Svensson
  • Patent number: 11485071
    Abstract: Apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers (3) of a build material (4) which can be consolidated by means of an energy source.
    Type: Grant
    Filed: February 14, 2019
    Date of Patent: November 1, 2022
    Inventors: Philipp Schumann, Denise Hiemann, Marc Bräuer, Johanna Windfelder, Timo Voigt
  • Patent number: 11478856
    Abstract: A selective laser solidification apparatus including; a powder bed onto which powder layers can be deposited, at least one laser module for generating a plurality of laser beams for solidifying the powder material deposited onto the powder bed, a laser scanner for individually steering each laser beam to solidify separate areas in each powder layer, and a processing unit. A scanning zone for each laser beam is defined by the locations on the powder bed to which the laser beam can be steered by the laser scanner. The laser scanner is arranged such that each scanning zone is less than the total area of powder bed and at least two of the scanning zones overlap. The processing unit is arranged for selecting, for at least one powder layers, which laser beam to use to scan an area of the powder layer located within a region wherein the seaming zones overlap.
    Type: Grant
    Filed: May 13, 2019
    Date of Patent: October 25, 2022
    Assignee: RENISHAW PLC
    Inventors: Ben Ian Ferrar, Ceri Brown
  • Patent number: 11472116
    Abstract: Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.
    Type: Grant
    Filed: July 11, 2019
    Date of Patent: October 18, 2022
    Assignee: Desktop Metal, Inc.
    Inventors: Jay Tobia, Nihan Tuncer, Aaron Preston, Ricardo Fulop, Michael A. Gibson, Richard Remo Fontana, Anastasios John Hart
  • Patent number: 11465351
    Abstract: A configurable build volume system for a powder bed fusion manufacturing process includes a chamber wall defining a chamber, the chamber wall extending in the X-, Y-, and Z-axis directions, a plurality of build platforms enclosed within the chamber, a plurality of adjustment mechanisms coupled to the plurality of build platforms such that each build platform is coupled to a separate adjustment mechanism, a sensor mounted within the chamber and configured to capture data regarding a Z-axis position of each of the plurality of build platforms, and a controller in electronic communication with the plurality of adjustment mechanisms and the sensor. The controller receives the Z-axis position data and generates a plurality of control signals to adjust a Z-axis position of each of the plurality of build platforms and each of the plurality of build platforms is actively and independently controlled by the controller.
    Type: Grant
    Filed: January 3, 2020
    Date of Patent: October 11, 2022
    Assignee: GM Global Technology Operations LLC
    Inventors: HyungMin Chae, Mark A. Smith, Richard J. Skurkis, Whitney A. Poling
  • Patent number: 11458680
    Abstract: A kit for the calibration of a head system of a power radiation source of an additive manufacturing device comprises: a calibration plate having a plurality of reference marks, and a firing support made from at least one material sensitive to the radiation of the source, this support leaving the reference marks of the calibration plate visible when it is in place thereon, characterized in that the firing support comprises a plurality of windows distributed in such a way as to become superposed with the various reference marks of the calibration plate and leave them visible when the firing support is in place on the calibration plate. There is also a method for calibrating such a system.
    Type: Grant
    Filed: June 19, 2018
    Date of Patent: October 4, 2022
    Assignee: ADDUP
    Inventors: Alexandre Roblin, Jean-Pierre Nicaise
  • Patent number: 11453160
    Abstract: A method of building a heat exchanger includes forming the heat exchanger with layer-by-layer additive manufacturing. A first hollow annulus is formed. A body of the heat exchanger is formed to be integrally connected to and grown upwards from the first hollow annulus. The body includes an exterior wall and a heat exchanger core disposed within the exterior wall. The body defines an interior that is cylindrically shaped with an axis oriented parallel to a direction of gravity. The first annulus is disposed on a gravitational bottom of the body. A second hollow annulus is formed integrally connected to and grown upwards from a gravitational top of the body. Residual powder is removed from a bottom of the heat exchanger.
    Type: Grant
    Filed: January 24, 2020
    Date of Patent: September 27, 2022
    Assignee: Hamilton Sundstrand Corporation
    Inventor: Paul M. Colson
  • Patent number: 11440265
    Abstract: Method for the additive production of a three-dimensional object (2) by selective exposure in successive layers and associated selective consolidation in successive layers of construction material layers composed of a construction material (3) that can be consolidated by means of an energy beam (4), wherein, as part of the additive production of the three-dimensional object (2) to be produced additively, a supporting structure (11) directly surrounding the three-dimensional object (2) produced or to be produced additively is formed by selective exposure in successive layers and associated selective pre-consolidation in successive layers of construction material layers composed of the construction material (3) that can be consolidated by means of the energy beam (4).
    Type: Grant
    Filed: December 13, 2017
    Date of Patent: September 13, 2022
    Inventor: Matthias Hofmann
  • Patent number: 11433659
    Abstract: The invention relates to a method for providing required construction material information in the context of producing at least one three-dimensional object using a generative layer construction device, having the following steps: accessing data of a layer to be applied in a first data set in which for each layer to be applied during the production process, it is indicated whether construction material is to be solidified selectively in the layer and if so, at which locations in said layer the construction material is to be solidified; dividing the area of the layer to be applied into sub-regions; assigning weighting factors to the sub-regions, and ascertaining a construction material quantity to be supplied to the coating device in order to apply the layer, wherein the construction material quantity is ascertained using the weighting factors assigned to individual sub-regions and is provided as required construction material information.
    Type: Grant
    Filed: November 25, 2016
    Date of Patent: September 6, 2022
    Assignee: EOS GmbH Electro Optical Systems
    Inventors: Markus Frohnmaier, Oliver Putz
  • Patent number: 11426928
    Abstract: The present disclosure relates to an additive manufacturing (AM) method for making a three-dimensional (3D) object, comprising a) the provision of providing a powdered polymer material (M) comprising at least one poly(ether ether ketone) (PEEK) polymer, and at least one poly(aryl ether sulfone) (PAES) polymer, b) the deposition of successive layers of the powdered polymer material; and c) the selective sintering of each layer prior to the deposition of the subsequent layer, wherein the powdered polymer material (M) is heated before step c) to a temperature Tp (° C.): Tp<Tg+40, wherein Tg (° C.) is the glass transition temperature of the PAES polymer, as measured by differential scanning calorimetry (DSC) according to ASTM D3418.
    Type: Grant
    Filed: September 14, 2018
    Date of Patent: August 30, 2022
    Inventors: Stéphane Jeol, Christopher Ward, Vito Leo
  • Patent number: 11426927
    Abstract: Example implementations relate to different mixtures of build materials deliverable during a three dimensional (3D) print operation. In some examples, a 3D print apparatus may include a delivery hopper to deliver build material to a print zone of the 3D print apparatus and a plurality of build material hoppers to which the delivery hopper is connected for receipt of at least one of a corresponding plurality of build materials. A controller of the 3D print apparatus may direct that variable proportions of a first build material relative to a second build material are receivable by the delivery hopper from the plurality of build material hoppers during the 3D print operation, where different mixtures of the variable proportions of the first build material and the second build material are deliverable to the delivery hopper during the 3D print operation.
    Type: Grant
    Filed: July 31, 2017
    Date of Patent: August 30, 2022
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: David R. Otis, Jr., Kevin E. Swier, Justin M. Roman, Wesley R. Schalk
  • Patent number: 11420396
    Abstract: According to examples, a three-dimensional (3D) fabrication system may include fabrication components and a controller. The controller may control the fabrication components to fabricate parts of a 3D object in a build envelope, the parts to be assembled together to form the object, and in which the parts are fabricated at locations corresponding to relative positions of the parts with respect to each other in the assembled object. The controller may also control the fabrication components to fabricate a cage around the parts in the build envelope.
    Type: Grant
    Filed: October 31, 2017
    Date of Patent: August 23, 2022
    Assignees: Hewlett-Packard Development Co., L.P., Instituto Atlantico
    Inventors: Marcelo Aita Riss, Alyne Gomes Soares Cantal, Thiago Barbosa Lima De Moura, Ana Patricia Del Angel, Jun Zeng, Scott White, Sebastia Cortes I Herms
  • Patent number: 11407906
    Abstract: A method for producing a surface coated with a coating having an improved coalescence, the method including: providing a composition comprising from 99.6% to 99.99% by weight of at least one powder of at least one polyarylene ether ketone and 0.01 to 0.4% by weight of a hydrophilic flow agent, the hydrophilic flow agent being hydrophilic silica; depositing the composition onto a surface forming a coated surface; and baking the coated surface to form a film on the surface.
    Type: Grant
    Filed: July 25, 2018
    Date of Patent: August 9, 2022
    Assignee: ARKEMA FRANCE
    Inventors: Benoît Brule, Hervé Ster, Cyrille Mathieu, Nadine Decraemer
  • Patent number: 11400646
    Abstract: The present invention relates to a method for producing an object, comprising the step of producing the object according to an additive production process from a construction material, wherein the construction material comprises a mixture of a plurality of powdery thermoplastic materials which are different from one another due to at least one mechanical property and at least one thermoplastic material is a thermoplastic polyurethane material. The invention also relates to an object obtained according to said method.
    Type: Grant
    Filed: April 23, 2018
    Date of Patent: August 2, 2022
    Inventors: Dirk Achten, Thomas Büsgen, Bettina Mettmann, Michael Kessler, Peter Reichert, Roland Wagner
  • Patent number: 11396134
    Abstract: There is provided improved laser sintering systems that increase the powder density and reduce anomalies of the powder layers that are sintered, that measure the laser power within the build chamber for automatic calibration during a build process, that deposit powder into the build chamber through a chute to minimize dusting, and that scrubs the air and cools the radiant heaters with recirculated scrubbed air. The improvements enable the laser sintering systems to make parts that are of higher and more consistent quality, precision, and strength, while enabling the user of the laser sintering systems to reuse greater proportions of previously used but unsintered powder.
    Type: Grant
    Filed: September 15, 2016
    Date of Patent: July 26, 2022
    Assignee: 3D SYSTEMS, INC.
    Inventors: David H. Cullen, Rafael Enrique Hidalgo
  • Patent number: 11358332
    Abstract: An additive manufacturing fusing module for use with an additive manufacturing base unit may include a housing, a reflector within the housing, a fusing unit within the housing, an electrical power connector connected to the heating device and having a terminal for releasable connection to a power source and a retainer coupled to the housing to releasably secure the housing to the additive manufacturing base unit.
    Type: Grant
    Filed: February 10, 2017
    Date of Patent: June 14, 2022
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Arthur H. Barnes, William F. Winters
  • Patent number: 11351598
    Abstract: A three-dimensional (3D) printer includes a heated printing surface and a multi-tool extrusion assembly. The multi-tool extrusion assembly includes a barrier extrusion assembly and a metal extrusion assembly. The barrier extrusion assembly includes: a first inlet adapter to receive a barrier material; a first torque-and-pinch assembly, coupled to the first inlet adapter, to receive the barrier material; and a first hot-end assembly, coupled to the first torque-and-pinch assembly, to receive the barrier material and extrude the barrier material to form an outer retaining barrier on the heated printing surface. The metal extrusion assembly includes: a second inlet adapter to receive a metal; a second torque-and-pinch assembly, coupled to the second inlet adaptor, to receive the metal; and a second hot-end assembly, coupled to the second torque-and-pinch assembly, to extrude the metal to form an inner metal filing on the heated printed surface within the outer retaining barrier.
    Type: Grant
    Filed: February 9, 2018
    Date of Patent: June 7, 2022
    Assignee: Raytheon Company
    Inventor: Bryan Robert Moosman
  • Patent number: 11344952
    Abstract: A three-dimensional additive manufacturing device is configured to emit a beam to a powder bed formed by laying a powder on a base plate to harden the powder bed selectively. A sensor is configured to detect the shape or the temperature of a surface of the powder bed or a modeling surface. A defect in laying of the powder or a defect in emission of the beam is corrected based on the detection result, before completion of forming of the next layer.
    Type: Grant
    Filed: August 8, 2017
    Date of Patent: May 31, 2022
    Inventors: Ryuichi Narita, Toshiya Watanabe, Akio Kondou, Hidetaka Haraguchi, Shuji Tanigawa, Masashi Kitamura
  • Patent number: 11318676
    Abstract: An additive manufacturing system includes a build chamber housing a recoater and a sintering laser. A build plate is moveable within the build chamber to accommodate growth of a part formed by the recoater and the sintering laser. At least one powder evacuation cavity at least partially surrounds a build volume of the build chamber. The build volume of the build chamber is defined between the build plate and the recoater and is configured to hold a sintered part and unsintered powder during an additive manufacturing build in the build chamber.
    Type: Grant
    Filed: October 22, 2018
    Date of Patent: May 3, 2022
    Assignee: Hamilton Sundstrand Corporation
    Inventors: David W. Morganson, Lawrence Binek
  • Patent number: 11279088
    Abstract: A build material management system for a 3D printing system is described in which a non-fused purged build material port is to output purged non-fused build material from a build material transportation system. An emptying of substantially all non-fused build material from at least a portion of the build material transportation system to the non-fused purged build material port in response to a received purge signal is controlled by processing circuitry of the build material management system.
    Type: Grant
    Filed: May 12, 2016
    Date of Patent: March 22, 2022
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Ismael Chanclon, Xavier Alonso, Marc Nicolau, Marc Morros, Xavier Miguel
  • Patent number: 11273600
    Abstract: A manufacturing method for generatively manufacturing a three-dimensional object by a layer-by-layer application and selective solidification of a building material includes applying a layer of the building material within a build area by means of a recoater moving in a recoating direction across the build area, selectively solidifying the applied layer of the building material at points corresponding to a cross-section of the object to be manufactured by means of a solidification device, and repeating the steps of applying and solidifying until the three-dimensional object is completed. A local action confined to a region between the recoating unit moving across the build area and the solidification device and/or compaction device moving behind the recoating unit across the build area is performed on the applied layer of the building material.
    Type: Grant
    Filed: March 1, 2017
    Date of Patent: March 15, 2022
    Assignee: EOS GmbH Electro Optical Systems
    Inventors: Stefan Paternoster, Stefan Grünberger, Peter Keller
  • Patent number: 11235520
    Abstract: A fabrication device includes a platform to receive layers of build material for production of a 3-dimensional solid representation of a digital model, a component to deposit layers of build material, and an imaging component to bind respective portions of the build material into cross sections representative of portions of data contained in the digital model. The first imaging component may be a programmable planar light source or a specialized refractive rastering mechanism, or other imaging system. The platform includes an infusion system for providing photocurable resin to the component being built. The object may be a powder composite component using any of a variety of powder materials or a plastic component.
    Type: Grant
    Filed: February 24, 2017
    Date of Patent: February 1, 2022
    Assignee: TRIO LABS, INC.
    Inventor: Adam T. C. Steege
  • Patent number: 11225016
    Abstract: Some examples include a method of operating an additive manufacturing machine including spreading a build material in a first direction across a build surface to form a layer, the layer having a thickness, decreasing a distance between a spread mechanism and the build surface, and translating the spread mechanism in a second direction opposite the first direction over the build surface to reduce the thickness of the layer.
    Type: Grant
    Filed: October 20, 2017
    Date of Patent: January 18, 2022
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventor: Arthur H Barnes
  • Patent number: 11224943
    Abstract: Systems and methods of adapting the geometrical shape of a laser beam in laser-based powder-bed fusion (PBF) are provided. An apparatus for laser-based powder-bed fusion includes a depositor that deposits a plurality of layers of a powder material. The apparatus further includes a laser beam source that generates a laser beam having a variable beam geometry. A laser application component applies the laser beam in one of a plurality of beam geometries to fuse the powder material to construct a build piece.
    Type: Grant
    Filed: March 7, 2018
    Date of Patent: January 18, 2022
    Inventor: Chor Yen Yap
  • Patent number: 11207827
    Abstract: In one example, a processor readable medium having instructions thereon that when executed cause an additive manufacturing machine to vary operating characteristics of a fusing laser beam at multiple different voxel locations in a layer of build material according to an energy dosage to be applied at each voxel location in an object slice, including multiple different energy dosages for corresponding multiple different voxel locations in the slice.
    Type: Grant
    Filed: March 29, 2017
    Date of Patent: December 28, 2021
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Cary G. Addington, David A. Champion, Mohammed S. Shaarawi, James McKinnell, Diane R. Hammerstad
  • Patent number: 11203160
    Abstract: Apparatuses and methods are provided that provide adaptive multi-process additive manufacturing systems for monitoring, measuring, and controlling additive manufacturing processes. A first laser (e.g., a fiber laser) is used for melting and consolidating the powder, and a second laser is utilized for dual purpose: (a) for metrology to measure the surface roughness, dimensional accuracy, material properties, etc., and (b) based on the evaluated measurements to take corrective actions (laser ablation, etc.) to attain the desired surface finish and dimensional accuracy. Various elements provide defect detection, defect identification, and defect response actions which remove defect related material or address under print or missing material in a build object.
    Type: Grant
    Filed: March 29, 2019
    Date of Patent: December 21, 2021
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: Hitesh D Vora, Subrata Sanyal
  • Patent number: 11192306
    Abstract: Examples include an apparatus for generating a three-dimensional object. The apparatus comprises at least one energy source, at least one build layer temperature sensor, and a controller. The controller is to control the at least one energy source to pre-fuse a portion of a build layer in a build area when a build layer temperature is less than a first temperature threshold. The controller is further to, after pre-fusing the portion of the build layer, control the at least one energy source to fuse the portion of the build layer in the build area when the build layer temperature is less than a second threshold.
    Type: Grant
    Filed: February 8, 2016
    Date of Patent: December 7, 2021
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Yan Zhao, Aja Hartman, Lihua Zhao
  • Patent number: 11186717
    Abstract: Provided are thermoplastic-nanoparticle compositions that exhibit enhanced powder and melt flow. The disclosed compositions, comprising nanoparticles being silylated, have particular application in additive manufacturing processes, such as selective laser sintering and other processes.
    Type: Grant
    Filed: December 20, 2016
    Date of Patent: November 30, 2021
    Inventors: Chiel Albertus Leenders, Samuel Ijsselmuiden, Johannes Gerardus Petrus Goossens, Bruke Jofore, Hao Gu
  • Patent number: 11179777
    Abstract: A device for fabricating a three-dimensional fabrication object includes a fabrication part, a flattening member to place powder in the fabrication part to form an excessively thick powder layer and remove the powder on the top surface side of the excessively thick powder layer multiple times to obtain a powder layer while moving in a direction orthogonal to a lamination direction of the powder layer, and a fabrication unit to bind the powder in the powder layer to form a laminar fabrication object, (wherein the laminar fabrication object is formed repeatedly to fabricate the three-dimensional fabrication object), wherein the amount of a layer thickness of the powder removed for the last time is less than that for any other time.
    Type: Grant
    Filed: April 30, 2018
    Date of Patent: November 23, 2021
    Assignee: RICOH COMPANY, LTD.
    Inventors: Yuta Koike, Shin Mizutani
  • Patent number: 11155676
    Abstract: A polymer powder composition for production of shaped objects via selective laser sintering includes a thermoplastic material, which is a polyester, wherein the powder has specific particles size distribution. The thermoplastic material has: has a crystallization half time of >30 s and <12 min at a supercooling of 50° C. below the peak melt temperature; a glass transition temperature Tg of >50° C.; a peak melt temperature Tp,m of >200° C.; an extrapolated first heating run melt onset temperature T ei,m of >5° C. above the extrapolated first cooling run crystallization end temperature Tef,c; and a degree of crystallinity of >10.0%. The polymer composition has a continuous use temperature of >100° C., and a low change of molecular weight during exposure to selective laser sintering processing temperatures.
    Type: Grant
    Filed: April 6, 2017
    Date of Patent: October 26, 2021
    Inventors: Zahir Bashir, Hao Gu
  • Patent number: 11155071
    Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support structure in the process of building objects that may be removed by rotating the support structure to a second orientation before removal, as well as novel support structures to be used within these AM processes. The support structures are fabricated in a first orientation and then rotated to the second orientation. The support structures are removed by passing through an outlet of the object.
    Type: Grant
    Filed: July 16, 2019
    Date of Patent: October 26, 2021
    Assignee: General Electric Company
    Inventors: Zachary David Fieldman, Daniel Joerger, Neal Dunham
  • Patent number: 11148360
    Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize breakable structures in the process of building objects, as well as novel breakable support structures to be used within these AM processes. A support structure includes a weakened portion and the object includes an outlet. The method includes breaking the removable support structure at the weakened portion into at least two parts.
    Type: Grant
    Filed: July 2, 2020
    Date of Patent: October 19, 2021
    Assignee: General Electric Company
    Inventor: Zachary David Fieldman
  • Patent number: 11141793
    Abstract: A device for fabricating a three-dimensional part by selectively melting a powder bed, the device including a first tank for containing a first powder and provided with a first powder dispenser valve, a second tank for containing a second different powder and provided with a second powder dispenser valve, a first and a second monitoring device for monitoring the quantity of first powder delivered by the first valve and the quantity of second powder delivered by the second valve, a mixer chamber in communication with the first and second valves and including a third powder dispenser valve, and a mixer for mixing the powder particles in the chamber, a support for receiving the powder delivered by the third valve and on which the parts is to be fabricated, a powder spreader for spreading powder on the support, and a heater member for locally melting the powder spread on the support.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: October 12, 2021
    Inventors: Jean-Baptiste Mottin, Guillaume Fribourg
  • Patent number: 11141912
    Abstract: A laser powder bed fusion additive manufacturing system having a powder dispenser that provides powder layers on a build platform; a laser fusion system that fuses the powder layers, wherein spatter particles are produce on the powder layers; and a powder bed sweeping system that sweeps the spatter particles from the powder layers. The powder bed sweeping system includes a brush that has bristles that contact the spatter particles and sweeps the spatter particles from the powder layers.
    Type: Grant
    Filed: October 10, 2019
    Date of Patent: October 12, 2021
    Assignee: Lawrence Livermore National Laboratory, LLC
    Inventors: Saad A. Khairallah, Gabe Guss, Eric B. Herbold, Wayne E. King, Manyalibo J. Matthews, Alexander M. Rubenchik, Otis R. Walton
  • Patent number: 11130282
    Abstract: Layers of build and support material on an intermediate transfer surface are exposed to a solvent using a solvent application station to make the build material tacky, without affecting the support material. Then, the intermediate transfer surface moves past a transfuse station (the transfuse station is positioned to receive the layers after exposure to the solvent) and a platen moves relative to the intermediate transfer surface to contact the platen to one of the layers on the intermediate transfer surface. The intermediate transfer surface transfers a layer of the build material and the support material to the platen each time the platen contacts the layers on the intermediate transfer surface at the transfuse station to successively form a freestanding stack of the layers of build and support material on the platen.
    Type: Grant
    Filed: May 31, 2019
    Date of Patent: September 28, 2021
    Assignee: Xerox Corporation
    Inventors: James A. Winters, Erwin Ruiz, Paul J. McConville, Jason M. LeFevre, Chu-heng Liu