Using Laser Sintering Of Particulate Material To Build Three-dimensional Product (e.g., Sls, Selective Laser Sintering, Etc.) Patents (Class 264/497)
  • 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
    Assignee: CONCEPT LASER GMBH
    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
    Assignee: CONCEPT LASER GMBH
    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: 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: 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
    Assignee: SOLVAY SPECIALTY POLYMERS USA, LLC
    Inventors: Stéphane Jeol, Christopher Ward, Vito Leo
  • 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
    Assignee: COVESTRO DEUTSCHLAND AG
    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
    Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.
    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: 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
    Assignee: DIVERGENT TECHNOLOGIES, INC.
    Inventor: Chor Yen Yap
  • 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: 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
    Assignee: SHPP GLOBAL TECHNOLOGIES B.V.
    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
    Assignee: SABIC GLOBAL TECHNOLOGIES B.V.
    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: 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: 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
    Assignee: SAFRAN AIRCRAFT ENGINES
    Inventors: Jean-Baptiste Mottin, Guillaume Fribourg
  • 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
  • Patent number: 11123819
    Abstract: A method of making an article is disclosed. According to the method, an energy beam is directed to a build location on a substrate, and a first powder material is delivered to the build location on the substrate and melted with the energy beam. A second powder material is delivered to the build location on the substrate over the first material and melted with the energy beam. The direction of the energy beam and delivery and melting of the first and second powders is repeated at multiple build locations on the substrate to form a solid surface of the article of the second material. The solid surface comprising the second material is subjected to a finishing process.
    Type: Grant
    Filed: September 25, 2017
    Date of Patent: September 21, 2021
    Assignee: HAMILTON SUNDSTRAND CORPORATION
    Inventors: Eric W. Karlen, William Louis Wentland
  • Patent number: 11123924
    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: February 20, 2018
    Date of Patent: September 21, 2021
    Assignee: RENISHAW PLC
    Inventors: David Roberts McMurtry, Christopher Sutcliffe, Robin Geoffrey Weston, Paul Campton, David John Whitton, David Beeby
  • Patent number: 11117317
    Abstract: A shaping method for a three-dimensional shaped product, including the following steps: 1. Setting a traveling distance of the squeegee to be a short distance that does not reach a chamber wall section, 2. Establishing location of wall layers connecting both ends at the chamber wall sections in a direction perpendicular to the traveling direction of the squeegee, within a traveling range based on the set traveling distance, or connecting to the ends on a powder feeder side at inner side of the chamber wall sections by a region to be sintered, from both sides of the region, 3. Forming powder layers by movement of the squeegee over the set traveling distance, 4. Forming sintered layers by irradiation with a beam on the formed powder layers, and forming wall layers by irradiation with a beam at the locations of the established wall layers, 5. Repeating steps 3 and 4.
    Type: Grant
    Filed: October 31, 2019
    Date of Patent: September 14, 2021
    Assignee: Matsuura Machinery Corp.
    Inventor: Seiichi Tomita
  • Patent number: 11117214
    Abstract: A laser irradiation device includes: a beam generation unit generating a laser beam; a scan mirror unit adjusting a direction of the laser beam transmitted from the beam generation unit; and a rotating mirror reflecting the laser beam of which the direction is adjusted by the scan mirror unit. The rotating mirror is provided to be rotatable so that the direction-adjusted laser beam is irradiated to an object to be processed while forming a linear laser beam on the object.
    Type: Grant
    Filed: April 7, 2015
    Date of Patent: September 14, 2021
    Inventor: Byoung-Chan Choi
  • Patent number: 11110517
    Abstract: The invention relates to a computer-assisted method for examining an input data set of a generative layer building device, comprising at least the following step: —comparing at least one parameter value in a computer-based model of an object that is to be produced using said generative layer building device, to a limiting parameter value which is an extreme value for the parameter able to be obtained in a method for producing the object, and particularly an extreme value for the parameter that can be obtained in a process-stable manner.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: September 7, 2021
    Assignee: EOS GmbH Electro Optical Systems
    Inventors: Vincent Antoine, Andreas Kahler, Christoph Mair
  • Patent number: 11097480
    Abstract: There are disclosed methods and apparatuses for 3D printing post-processing. The methods and apparatuses provide a container for an additive manufacturing system, the container for receiving a build volume of fused and unfused build material. The container comprises a connector for connecting the container to a pressure source, and at least one air hole to allow passage of air into or out of the container. When the connector is connected to the pressure source, air flows through the container between the connector and the at least one air hole so as to remove unfused build material from the container and to help cool the volume of build material.
    Type: Grant
    Filed: May 12, 2016
    Date of Patent: August 24, 2021
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Justin M. Roman, Xavier Alonso Becerro, Ismael Chanclon Fernandez
  • Patent number: 11084132
    Abstract: 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: Grant
    Filed: October 26, 2017
    Date of Patent: August 10, 2021
    Assignee: General Electric Company
    Inventors: David Charles Bogdan, Jr., Jason Harris Karp, William Thomas Carter
  • Patent number: 11077463
    Abstract: The invention relates to a method for the layered manufacturing of a structural component from powder, comprising the following steps: establishing at least one parameter (t) of a depression (1) in a produced layer (2) of the structural component; smoothing out the depression (1) if the at least one parameter (t) exceeds a predetermined value; and filling the smoothed-out depression (1) with powder (13).
    Type: Grant
    Filed: November 10, 2011
    Date of Patent: August 3, 2021
    Assignee: MTU AERO ENGINES AG
    Inventors: Thomas Hess, Erwin Bayer
  • Patent number: 11065860
    Abstract: A method of printing a 3D object includes feeding one or more preformed materials from a feed outlet into a build zone in which a hot spot is located and using the hot spot to selectively heat the one or more preformed materials to a viscous state. Object layers are formed by depositing portions of the preformed materials on a build surface, or on another object layer on the build surface, while effecting relative motion between the build surface and the feed outlet.
    Type: Grant
    Filed: August 12, 2016
    Date of Patent: July 20, 2021
    Assignee: CORNING INCORPORATED
    Inventors: Christopher William Drewnowski, Michael Thomas Gallagher, Scott Michael Jarvis, Xinghua Li, Moussa N'Gom, Robert Stephen Wagner, Nicholas Ryan Wheeler
  • Patent number: 11045876
    Abstract: An additive manufacturing process includes applying a layer of a building material on a building support or an already applied and selectively solidified layer and selectively solidifying the applied layer by electromagnetic radiation or particle radiation. All positions in the layer that correspond to a cross-section of the object are scanned by electromagnetic radiation or particle radiation such that at these positions the powder is melted at least at its surface. At least one cross-section includes an inner region and a surface region. The step of applying a layer and the step of selectively solidifying the layer are repeated until all cross-sections of the object are solidified. At least a portion of the surface region is scanned at least twice before scanning of the inner region starts.
    Type: Grant
    Filed: March 10, 2016
    Date of Patent: June 29, 2021
    Assignee: EOS GmbH Electro Optical Systems
    Inventor: Thomas Hoferer
  • Patent number: 11045976
    Abstract: An apparatus for producing three-dimensional objects is provided including a bonding liquid applier and a controller. The bonding liquid applier applies a bonding liquid to a powder layer to form a bonded layer. The controller controls the bonding liquid applier to repeatedly form an (n)th bonded layer by applying a predetermined amount of the bonding liquid per unit area, in multiple times, to a new bonding region in an (n)th powder layer, below which an (n?1)th bonded layer does not exist, and applying the predetermined amount of the bonding liquid per unit area, in a smaller number of times than the multiple times, to an existing bonding region in the (n)th powder layer, below which the (n?1)th bonded layer exists, while increasing a numeral (n) representing an integer of 1 and above in increment of 1, to laminate multiple bonded layers into a three-dimensional object.
    Type: Grant
    Filed: February 23, 2017
    Date of Patent: June 29, 2021
    Assignee: Ricoh Company, Ltd.
    Inventors: Takafumi Sasaki, Shinichiroh Satoh
  • Patent number: 11045875
    Abstract: An additive manufacturing method may involve: Providing a first and a second material, the second material capable of reacting with the first material to form a reaction product; forming at least the first material into a first layer; subjecting at least a portion of the first layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between at least the first and second materials to form a portion of the article, the portion of the article comprising the reaction product; forming a second layer of at least the first material on the first layer; and subjecting at least a portion of the second layer to energy in the presence of the second material, the energy being sufficient to initiate a reaction between the first and second materials to form an additional portion of the article.
    Type: Grant
    Filed: November 8, 2019
    Date of Patent: June 29, 2021
    Assignee: Elementum 3D, Inc.
    Inventors: Jacob S. Nuechterlein, Jeremy Joseph Iten
  • Patent number: 11034086
    Abstract: Apparatus for producing an object by means of additive manufacturing, comprising: a process chamber for receiving on a build surface of a build plate a bath of powdered material which can be solidified; a support for positioning said build plate in relation to a surface level of said bath of powdered material; a solidifying device for solidifying a selective part of said material; and a homing device for moving said build surface, by said support, to a home position such that said object can be build on said build surface of said build plate, wherein said homing device comprises a homing member which can be displaced along said build surface of said build plate, wherein said homing device is designed for moving said build surface to said home position until a measured force for displacing said homing member is within a pre-determined range. Method for producing an object by means of additive manufacturing.
    Type: Grant
    Filed: September 18, 2017
    Date of Patent: June 15, 2021
    Assignee: Additive Industries B.V.
    Inventors: Martijn Robert Hamers, Rob Peter Albert Van Haendel, Mark Herman Elise Vaes
  • Patent number: 11027368
    Abstract: A method of manufacturing an object by additive manufacturing is provided. The method includes lowering a build platform having a given layer of build material to powder provided on a window. The powder is irradiated to form a subsequent layer that corresponds to the given layer. The method then includes solidifying the subsequent layer, and raising the build platform and the subsequent layer away from the window. The steps are repeated until the desired object is formed.
    Type: Grant
    Filed: August 2, 2017
    Date of Patent: June 8, 2021
    Assignee: General Electric Company
    Inventors: Todd Jay Rockstroh, William Thomas Carter