Using Laser Sintering Of Particulate Material To Build Three-dimensional Product (e.g., Sls, Selective Laser Sintering, Etc.) Patents (Class 264/497)
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Publication number: 20140283936Abstract: A device for expelling/containing a predetermined liquid. The device configured to be built into a liquid tank operable at low or zero gravity and comprising a unitary three-dimensional sponge structure. The sponge structure comprises a set of substantially wire-like elements that extend between a peripheral area of the sponge structure and an area for expelling/containing liquid. The wire-like elements are substantially oriented in the direction of flow of the fluid within the device. The wire-like elements are connected together by crosspieces and are arranged such that the capillary gradient is positive or zero in the direction of flow of the fluid from the peripheral area to the area for expelling/containing liquid.Type: ApplicationFiled: October 18, 2012Publication date: September 25, 2014Inventor: Louis Dandaleix
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Publication number: 20140259588Abstract: A template for radiography and methods of using and making a template are described. The template can include a contoured sheet having first portions and second portions. The first portions are radiodense and the second portions are radiolucent to provide markings on a radiograph. At least one surface of the contoured sheet can correspond to at least one surface of a target part to provide alignment of the contoured sheet to the target part.Type: ApplicationFiled: March 14, 2013Publication date: September 18, 2014Inventors: James Raphord Barrett, Jason Armstrong, Doug Nikolas, Andrew Isaac Deceuster, Lawrence Lang
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Publication number: 20140271326Abstract: 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: ApplicationFiled: March 14, 2014Publication date: September 18, 2014Applicant: 3D Systems, Inc.Inventors: David H. Cullen, Rafael Enrique Hidalgo
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Publication number: 20140265046Abstract: One variation of a method for detecting a temperature at a laser sintering site within a field of view of an image sensor within a laser sintering device includes: based on a selected fuse temperature for a laser sintering build material, setting a first shutter speed for the image sensor, the first shutter speed corresponding to a detectable range of temperatures including an anticipated temperature at the laser sintering site; at a first time, capturing a first digital image of the laser sintering site with the image sensor at a first shutter speed; and correlating a light intensity of a pixel within the first digital image with a first temperature at the laser sintering site at the first time based on the first shutter speed.Type: ApplicationFiled: March 14, 2014Publication date: September 18, 2014Applicant: Matterfab Corp.Inventors: Matthew Burris, Andrew Dolgner
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Publication number: 20140265048Abstract: One variation of a method for constructing a three-dimensional structure within a additive manufacturing apparatus includes: reading an identifier from a cartridge transiently loaded into the additive manufacturing apparatus; initiating a build cycle; dispensing a layer of powdered material from the cartridge into a build chamber of the additive manufacturing apparatus; during the build cycle, selectively fusing regions of the layer; in response to completion of the build cycle, dispensing a volume of loose powdered material from the build chamber into the cartridge; and over a computer network, updating a computer file with data pertaining to the build cycle, the computer file specific to the cartridge and accessed according to the identifier.Type: ApplicationFiled: March 14, 2014Publication date: September 18, 2014Applicant: Matterfab Corp.Inventors: Matthew Burris, Andrew Dolgner
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Publication number: 20140265047Abstract: One variation of a method for controlling construction of a part over a build platform within a laser sintering device including an opaque door configured to seal the build platform within a build chamber includes: setting a lamp within the build chamber to an off state; detecting electromagnetic radiation within the build chamber based on an output of an optical sensor within the build chamber; in response to detection of electromagnetic radiation above a threshold flux, interrupting construction of the part within the build chamber; in response to detection of electromagnetic radiation below the threshold flux, setting the lamp to an on state to illuminate the build chamber; at an image sensor within the build chamber, capturing a digital image of the laser sintering site; and rendering the digital image on a digital display arranged on an exterior surface of the laser sintering device.Type: ApplicationFiled: March 14, 2014Publication date: September 18, 2014Applicant: Matterfab Corp.Inventors: Matthew Burris, Andrew Dolgner
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Publication number: 20140265049Abstract: One variation of a method for constructing a three-dimensional structure within a additive manufacturing apparatus includes: reading an identifier from a cartridge transiently loaded into the additive manufacturing apparatus; based on the identifier, retrieving from a computer network a laser fuse profile for powdered material contained within the cartridge; leveling a volume of powdered material dispensed from the cartridge into a layer of substantially uniform thickness across a build platform within the additive manufacturing apparatus; and selectively fusing regions of the layer according to a fuse parameter defined in the laser fuse profile.Type: ApplicationFiled: March 14, 2014Publication date: September 18, 2014Applicant: Matterfab Corp.Inventors: Matthew Burris, Andrew Dolgner
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Publication number: 20140271965Abstract: A selective laser solidification apparatus including: a powder bed onto which a powder layer can be deposited, a gas flow unit for passing a flow of gas over the powder bed along a gas flow direction, a laser scanning unit for scanning a laser beam over the powder layer to selectively solidify at least part of the powder layer to form at least one object and a processing unit for selecting a scanning sequence of the laser beam based on the gas flow direction.Type: ApplicationFiled: February 12, 2014Publication date: September 18, 2014Inventor: Ben Ian FERRAR
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Publication number: 20140265045Abstract: 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: ApplicationFiled: March 14, 2014Publication date: September 18, 2014Applicant: 3D Systems, Inc.Inventors: David H. Cullen, Rafael Enrique Hidalgo
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Patent number: 8834777Abstract: The present invention relates to the use of a powder which comprises specific polyesters for shaping processes, and to moldings produced powder. The shaping processes are layer-by-layer processes which use powder, which comprises selectively melting regions of a powder layer by applying electromagnetic energy. Selectivity can although there is no intention to restrict the invention thereto be achieved via a mask, or application of an inhibitor, of an absorber or of a susceptor, or via focusing of the energy input. After cooling, the regions then solidified can be removed as moldings from the powder bed. The process occurs by using a polyester powder obtained from an alcohol and from a diacid with no use of any aromatic monomer unit. These polyester powders combine high crystallinity and low melting point, and makes the construction process more reliable while good component quality, mechanical properties, density, dimensional accuracy, and low shrinkage are realized.Type: GrantFiled: November 17, 2006Date of Patent: September 16, 2014Assignee: Evonik Degussa GmbHInventors: Ulrich Simon, Sylvia Monsheimer, Maik Grebe, Heinrich Temme
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Publication number: 20140252687Abstract: A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.Type: ApplicationFiled: March 5, 2013Publication date: September 11, 2014Applicant: LAWRENCE LIVERMORE NATIONAL SECURITY, LLCInventors: Bassem S. EL-DASHER, Andrew BAYRAMIAN, James A. DEMUTH, Joseph C. FARMER, Sharon G. TORRES
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Publication number: 20140221566Abstract: Powder compositions and articles and methods of forming articles from powder compositions are provided. In one embodiment the powder compositions include at least one polyester polymer powder and an amount of reinforcing particles having an aspect ratio of preferably at least about 5:1. In another embodiment the powder compositions include at least one medium-high melting temperature, aromatic and crystalline polyester polymer powder. In a preferred embodiment, the powder composition is capable of being formed, via a laser sintering process, into a three-dimensional article that exhibits one or more desirable mechanical properties in an elevated temperature environment.Type: ApplicationFiled: November 25, 2013Publication date: August 7, 2014Applicant: VALSPAR SOURCING, INC.Inventor: Raffaele Martinoni
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Patent number: 8794263Abstract: A filter assembly for an additive manufacturing apparatus has a housing defining a gas inlet and a gas outlet. A filter element is located within the housing between the gas inlet and the gas outlet. The assembly includes valves that can be actuated to seal the gas inlet and the gas outlet. Additionally the assembly has a fluid inlet for allowing ingress of a fluid into the housing. The assembly allows a filter element, which may contain volatile particles, to be changed safely. By sealing the gas inlet and outlet and flooding the housing with a suitable fluid, volatile particles captured by the filter can be neutralised.Type: GrantFiled: September 7, 2009Date of Patent: August 5, 2014Assignee: MTT Technologies LimitedInventors: Simon Peter Scott, Christopher Sutcliffe
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Publication number: 20140202163Abstract: Additive manufacturing techniques may be utilized to construct effusion plates. Such additive manufacturing techniques may include defining a configuration for an effusion plate having one or more internal cooling channels. The manufacturing techniques may further include depositing a powder into a chamber, applying an energy source to the deposited powder, and consolidating the powder into a cross-sectional shape corresponding to the defined configuration. Such methods may be implemented to construct an effusion plate having one or more channels with a curved cross-sectional geometry.Type: ApplicationFiled: January 23, 2013Publication date: July 24, 2014Applicant: GENERAL ELECTRIC COMPANYInventors: Thomas Edward Johnson, Christopher Paul Keener, Heath Michael Ostebee, Daniel Gerritt Wegerif
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Patent number: 8784723Abstract: A method of three-dimensional fabrication of an object is disclosed. The method comprises: forming a plurality of layers in a configured pattern corresponding to the shape of the three-dimensional object, at least one layer of the plurality of layers being formed at a predetermined and different thickness selected so as to compensate for post-formation shrinkage of the layer along a vertical direction. In various exemplary embodiments of the invention spread of building material of one or more layers is diluted at least locally such as to maintain a predetermined thickness and a predetermined planar resolution for the layer.Type: GrantFiled: April 1, 2007Date of Patent: July 22, 2014Assignee: Stratasys Ltd.Inventor: Eduardo Napadensky
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Patent number: 8784721Abstract: A method of manufacturing three-dimensional objects by laser sintering is provided, the object is formed by solidifying powder material layer by layer at locations in each layer corresponding to the object by means of laser radiation, wherein an IR-radiation image in an applied powder layer is detected, characterized in that defects and/or geometrical irregularities in the applied powder layer are determined on the basis of the IR-radiation image.Type: GrantFiled: November 25, 2008Date of Patent: July 22, 2014Assignee: EOS GmbH Electro Optical SystemsInventors: Jochen Philippi, Thomas Mattes
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Patent number: 8784720Abstract: The present invention relates to a method and a device for manufacturing a three-dimensional object, wherein the object is generated by successively solidifying single layers of fluid or powdery solidifiable building material by the action of electromagnetic radiation. The method comprises steps for emitting a first pulsed electromagnetic radiation onto a first area of a layer of the building material, and for emitting a second continuous electromagnetic radiation onto a second area of the layer of the building material.Type: GrantFiled: February 22, 2011Date of Patent: July 22, 2014Assignee: EOS GmbH Electro Optical SystemsInventors: Johann Oberhofer, Joachim Göbner, Hans-Ulrich Büse
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Publication number: 20140197579Abstract: An additive layer manufacturing method for producing a shaped article, comprising providing a powdered thermoplastic polymer material (7, 8) having a re-solidification temperature at most 10% below its melting temperature on the Celsius scale, depositing successive layers of the powdered polymer material (7, 8) and selectively sintering each layer prior to deposition of the subsequent layer so as to form the article, wherein during its production the article is maintained at a temperature above the glass transition temperature and significantly below the re-solidification temperature of the polymer.Type: ApplicationFiled: May 9, 2012Publication date: July 17, 2014Applicant: EADS UK LIMITEDInventor: Jonathan Meyer
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Patent number: 8778255Abstract: A component, in particular an engine component, which has at least one mark with a predetermined three-dimensional shape for determining a stress in the component and where the component is constructed by a generative manufacturing method, is disclosed.Type: GrantFiled: July 31, 2012Date of Patent: July 15, 2014Assignee: MTU Aero Engines GmbHInventors: Joachim Bamberg, Roland Hessert
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Publication number: 20140186098Abstract: A powder-derived, non-finished work piece includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.Type: ApplicationFiled: December 28, 2012Publication date: July 3, 2014Applicant: UNITED TECHNOLOGIES CORPORATIONInventors: Sergey Mironets, Lyutsia Dautova, Joseph Ott, Christopher F. O'Neill, Robert P. Delisle, Jesse R. Boyer, Agnes Klucha, Louis Porretti
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Patent number: 8747538Abstract: A photovoltaic crucible mold release compound includes a powder mixture comprising silicon nitride powder having 1 ppm of impurities or less and silicon dioxide 1 ppm of impurities or less mixed in with the silicon nitride powder until the gray of the silicon nitride powder turns lighter in color which is from 1% silicon dioxide in weight up to 50% silicon dioxide in weight. Also included is a binder having a liquid. The powder mixture is mixed with the binder. The binder can be ethanol, water or alcohol. A photovoltaic crucible mold release compound can also include a photovoltaic crucible mold, so that the mold release compound is applied to an inside surface of the photovoltaic crucible mold to a thickness of 75 to 1500 microns.Type: GrantFiled: September 20, 2011Date of Patent: June 10, 2014Inventor: Chung-Hou Tony Hsiao
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Patent number: 8739409Abstract: The invention relates to a method for manufacturing products by applying material at least partially in layers to form a structure, in particular by selective laser melting (SLM), said method comprising the steps of: (a) providing a base plate, (b) applying a layer of a curable material, (c) selectively curing predetermined zones of the applied layer on the basis of geometrical data of the product, (d) repeating steps (b) and (c) until the geometry of a first partial volume of the product has been created in the form of a cured material and (e) removing the uncured material. According to the invention, a reference mark is provided, the unit formed by the base plate and the first volume zones is clamped into a specific position by means of the reference mark and the respective second partial volume of the respective product is cut from the base plate, preferably by machining, in particular CNC milling.Type: GrantFiled: July 2, 2009Date of Patent: June 3, 2014Assignee: BEGO Medical GmbHInventors: Carsten Vagt, Ralf Wehning
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Publication number: 20140147328Abstract: A method for manufacturing a three-dimensional shaped object, comprising: (i) forming a powder layer on a base plate by a sliding movement of a squeegee blade, followed by forming a solidified layer by irradiating a predetermined portion of the powder layer with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, steps (i) and (ii) being repeatedly performed, wherein machining is performed at least once on an outer surface of a shaped object precursor obtained during manufacturing, and after machining, at least one solidified layer is formed, and followed by upper face machining to remove a raised solidified portion generated at a peripheral edge of the solidified layer.Type: ApplicationFiled: May 22, 2012Publication date: May 29, 2014Applicant: PANASONIC CORPORATIONInventors: Satoshi Abe, Isamu Matsumoto, Masataka Takenami, Isao Fuwa, Yoshikazu Higashi, Yoshiyuki Uchinono, Norio Yoshida
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Patent number: 8734694Abstract: A device (1) for manufacturing a three-dimensional object by a layer wise solidification of a building material at positions in the respective layers that correspond to the object is provided. A feed (96) that supplies the building material to a building space (10) in the device (1) and at least two filler portions (98a, 98b) that are provided at the feed (96) and are independent from one another are provided, wherein one connector (99a, 99b) is provided for each building material supply container (100a, 100b) in order to supply the building material from outside of the device (1).Type: GrantFiled: May 24, 2012Date of Patent: May 27, 2014Assignee: EOS GmbH Electro Optical SystemsInventors: Hans Perret, Thomas Halder, Jochen Philippi, Peter Keller, Gerd Cantzler, Michael Göth, Siegfried Schimitzek, Andrea Weichselbaumer
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Publication number: 20140140882Abstract: A method and apparatus for manufacturing a three-dimensional object by additive layer manufacturing. The method includes providing layers of material in powder form on a support inside a chamber, and irradiating each layer with a beam before providing the subsequent layer. A gas atmosphere is maintained inside the chamber during the irradiation steps. The pressure and/or the composition of the gas atmosphere is controlled where at least two different gas atmospheres having different predetermined pressures and/or compositions are inside the chamber during irradiation of the layers, the beam spot size on the layers is controlled such that at least two different beam spot sizes are utilized during irradiation, and/or the temperature of the gas atmosphere inside the chamber and/or of the layer being irradiated is controlled such that at least two different temperatures of the gas atmosphere and/or of the layer being irradiated are present during irradiation of the layers.Type: ApplicationFiled: November 11, 2013Publication date: May 22, 2014Inventor: Freerk Syassen
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Publication number: 20140121327Abstract: The invention relates to the use of a powder made of a polymer, which of two or more components with functionalities suitable for Diels-Alder reactions, or of a powder mixture (dry blend) made of powders respectively of at least one of the reactive components, where these together enter into the Diels-Alder reaction with one another and are capable of a retro-Diels-Alder reaction, in a rapid-prototyping process. The invention further relates to moldings produced with use of said polymer powder through a layer-by-layer shaping process in which regions of a powder layer are melted selectively. The molding here can be removed from the powder bed after cooling and hardening of the regions previously melted layer-by-layer.Type: ApplicationFiled: June 5, 2012Publication date: May 1, 2014Applicant: Evonik Roehm GmbHInventors: Friedrich Georg Schmidt, Stefan Hilf, Jiawen Zhou, Nathalie Guimard, Christopher Barner-Kowollik, Kim Klaus Oehlenschlaeger
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Patent number: 8709330Abstract: A method and apparatus is present for manufacturing parts. A powder material is comprised of a polymer that is semi-crystalline. The powder material has an overlap between a melting temperature range and a crystallization temperature range. The powder material also has a size particular distribution that is substantially a Gaussian distribution, a particle shape that is substantially spherical, and a desired melt flow rate that is less than a temperature at which the powder material begins to chemically break down. The powder material is selected to form a selected powder material. A part is manufactured using an energy delivery system and the selected powder material.Type: GrantFiled: January 6, 2009Date of Patent: April 29, 2014Assignee: The Boeing CompanyInventors: Christopher S. Huskamp, Brett Ian Lyons
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Publication number: 20140091036Abstract: A method for constructing a spiral tube support apparatus used in countercurrent chromatography, improvements to countercurrent chromatography tube support design, and methods of using the improved countercurrent chromatography apparatus are described. The spiral tube support apparatus may be constructed by a shape forming process such as a three dimensional printing process that in turn uses a laser sintering technique, and can be made out of any easily formed material. Shape changes on both the tube support and the top improve the performance of the tube support and ease of manufacturing. The improved tube support and new method of creation permit use in both micro or macro scale preparations and use in small or large molecule preparations. In particular, specific solvent systems are described that permit purification of proteins.Type: ApplicationFiled: December 1, 2013Publication date: April 3, 2014Applicant: CC Biotech LLCInventors: Martha Knight, Thomas Finn
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Patent number: 8684069Abstract: A method of fabricating a metal part by selectively melting a powder, the method including: building up layer by layer on a plate and simultaneously with the part, at least one holder and support element for the part, the element being spaced apart and distinct from the part and being separated therefrom by a gap filled with non-melted powder; after the part has been made completely, removing at least some of the powder remaining in the gap between the part and the element, for example by suction, blowing, or vibration; and separating the part from the plate.Type: GrantFiled: July 1, 2011Date of Patent: April 1, 2014Assignee: SNECMAInventors: Jean-Baptiste Mottin, Beryl Cassandre Anne Mereaux, Sophie Martine Jobez, Olivier Chantoiseau, Bruno Le Razer
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Publication number: 20140086780Abstract: Disclosed are methods and systems for improving the quality, throughput and efficiency of Solid Free Form manufacture of implant components.Type: ApplicationFiled: September 20, 2013Publication date: March 27, 2014Applicant: CONFORMIS, INC.Inventors: Bob Miller, David Hesketh, Ernest A. Dion
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Publication number: 20140077421Abstract: A disclosed additive manufacturing machine includes a fixed platform defining a work surface for supporting fabrication of a part and a housing defining a chamber over the work surface. A material applicator is supported on the housing for depositing material onto the work surface. An energy directing device is also supported on the housing and directs energy within the chamber to form a part. The housing is movable relative to the work surface therefore moves the energy producing device relative to the work surface to maintain a distance between the energy directing device and a surface of the part during fabrication.Type: ApplicationFiled: September 14, 2012Publication date: March 20, 2014Inventor: Alan B. Minick
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Publication number: 20140079916Abstract: An apparatus for the simultaneous layer-by-layer production of three-dimensional objects, containing a construction chamber with a height-adjustable construction platform, an apparatus for applying, to the construction platform, a layer of a material that can be hardened by exposure to electromagnetic radiation, and irradiation equipment. The irradiation equipment contains a radiation source emitting electromagnetic radiation, a control unit and a lens located in a beam path of the electromagnetic radiation, for irradiating sites within the layer that correspond to an object, in which a cooling element can be produced at the same time as the object. A process for the layer-by-layer production of a three-dimensional object in the apparatus, involves producing an object and a cooling element at the same time.Type: ApplicationFiled: September 17, 2013Publication date: March 20, 2014Applicant: Evonik Industries AGInventors: Maik GREBE, Wolfgang Diekmann, Sigrid Hessel-Geldmann, Juergen Kreutz
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Publication number: 20140077422Abstract: A disclosed additive manufacturing machine includes a work surface for supporting fabrication of part and a housing defining a chamber over the work surface. A material applicator supported on the housing deposits material onto the work surface and a blocker plate disposed between the material applicator and the work surface for blocking a portion of material deposited by the material applicator. An energy directing device is supported on the housing and directing energy within the chamber to form the part.Type: ApplicationFiled: September 19, 2012Publication date: March 20, 2014Applicant: PRATT & WHITNEY ROCKETDYNE, INC.Inventor: Alan B. Minick
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Patent number: 8673203Abstract: A method for depositing material at an intersection region (116) of at least two surfaces (102,104,106,108,110) of a component (100). The method comprises a first deposition process providing material at said intersection and directing an energy beam (114) toward the intersection region to join the material to the component. The beam is maintained at an obtuse angle relative to at least two of the surfaces such that substantially all of the working area of the beam is incident upon the intersection region.Type: GrantFiled: August 23, 2010Date of Patent: March 18, 2014Assignee: Rolls-Royce PLCInventors: Daniel Clark, Christopher A. Simmons, Mark D. Hancock
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Patent number: 8658078Abstract: A method is provided, by which a three-dimensional object is manufactured by a subsequent solidification of layers of a building material in powder form at the positions in the respective layer that corresponds to the cross-section of the object by means of the action of a laser or another energy source, wherein as building material in powder form a material is used which contains the old powder that has remained as unsolidified powder in the manufacturing of one or more previously formed objects and a proportion of new powder that has not been used before in any manufacturing process, characterized in that the building material in powder form is mechanically consolidated when a layer is applied.Type: GrantFiled: February 14, 2011Date of Patent: February 25, 2014Assignee: EOS GmbH Electro Optical SystemsInventors: Jochen Weidinger, Frank Muller, Florian Pfefferkorn
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Publication number: 20140050921Abstract: Materials and methods is present for manufacturing fiber reinforced parts. A powder material comprising a matrix material of a size particular distribution comprising substantially oriented fiber of a predetermined length distribution and diameter (L/D). A manufactured part that has substantially randomly oriented fiber is provided using an energy delivery system and the powder material.Type: ApplicationFiled: December 7, 2012Publication date: February 20, 2014Applicant: THE BOEING COMPANYInventor: THE BOEING COMPANY
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Publication number: 20140035205Abstract: A powder rapid prototyping apparatus includes a decompressable chamber, a thin layer forming section which supplies powder material from a powder material housing container provided in the chamber to form a thin layer of the powder material, an energy beam source for heating which outputs energy beam for heating which sinters or melts and models the thin layer of the powder material, and a control section which controls the modeling, wherein the control section exposes the powder material to the decompressed atmosphere before starting modeling, and houses the powder material in the powder material housing containers in a divided manner.Type: ApplicationFiled: December 20, 2012Publication date: February 6, 2014Applicant: ASPECT INC.Inventors: Masashi HAGIWARA, Masahiro SASSA
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Publication number: 20140015172Abstract: An additive layer manufacturing system and method are provided. The system includes a powder delivery system providing at least one powder feed from a powder stock to a powder exit adjacent a deposition point. The powder delivery system further comprises at least one valve system proximal to the powder exit for controlling the flow of the at least one powder feed at the deposition point.Type: ApplicationFiled: March 20, 2012Publication date: January 16, 2014Applicant: BAE SYSTEMS plcInventors: Jagjit Sidhu, Andrew David Wescott
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Publication number: 20140010908Abstract: There is provided a method for manufacturing a three-dimensional shaped object, comprising the steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, the steps (i) and (ii) being repeatedly performed, wherein the three-dimensional shaped object is manufactured such that it has three different solidified portions of high-density, intermediate-density and low-density solidified portions in at least a part of the object, and wherein the intermediate-density solidified portion is formed to be located in a part of a surface of the three-dimensional shaped object.Type: ApplicationFiled: March 15, 2012Publication date: January 9, 2014Applicant: PANASONIC CORPORATIONInventors: Isamu Matsumoto, Satoshi Abe, Masataka Takenami, Yoshiyuki Uchinono
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Publication number: 20130341838Abstract: A method provides a device having a feeder vessel, a building vessel with a bottom and a fabrication plate that is movable in vertical translation, a transfer system suitable for depositing powder from the feeder vessel to the building vessel as a powder layer of constant thickness, and a high energy beam optical system suitable for scanning the surface of the deposited powder layer. A powder is placed in the feeder vessel. A first series of powder layers is deposited on the fabrication plate. The particles of powder are melted or sintered to form a plurality of columns of material that are separated from one another by particles of powder. A second series of layers of powder is deposited on the first series of layers of powder particles to form a single-piece element. A thermal insulation platform is formed between the fabrication plate and said single-piece element.Type: ApplicationFiled: June 3, 2013Publication date: December 26, 2013Inventors: Thomas VILARO, Olivier CHANTOISEAU, Sebastien RIX
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Publication number: 20130320598Abstract: There is disclosed herein a method of printing a printed body to be formed from a plurality of layers by 3D printing, the method comprising: depositing a plurality of layers of material, the material in the layers being bonded to form a body from the layers, the body including a mold that at least partially defines a mold cavity having an inner surface substantially corresponding to at least a portion of the external surface of an object to be molded in the mold cavity, wherein: the object to be molded is to be formed by infiltrating a matrix material held in the mold cavity with an infiltration material; and the body includes at least a portion of the matrix material to be held in the mold cavity, the at least a portion of the matrix material being deposited and bonded in the plurality of layers during printing of the body.Type: ApplicationFiled: November 25, 2011Publication date: December 5, 2013Inventors: William Brian Atkins, Gary Eugene Weaver
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Publication number: 20130323473Abstract: Processes for fabricating secondary structures of gas turbine engines from polymer-based materials, and secondary structures formed thereby. The processes entail performing an additive manufacturing technique to produce a secondary structure of a gas turbine engine. The additive manufacturing technique directly produces the secondary structure from a polymer-based material to have a complex three-dimensional shape characterized by portions that lie in different planes.Type: ApplicationFiled: May 30, 2012Publication date: December 5, 2013Applicant: GENERAL ELECTRIC COMPANYInventors: Benjamin Allen Dietsch, James Michael Kostka, David Edward Dale, Jared Matthew Wolfe
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Publication number: 20130323416Abstract: The invention relates to heat treatment of polymorphic semicrystalline or crystallizable polymers to increase the content of the highest melting crystalline form. Such heat treatment results in a polymer powder that has a consistent, uniform melting range, improved flow and improved durability of the powder particle size for applications that require powder flow at elevated temperatures. In addition to improved powder properties, the articles produced from the powders also exhibit better physical properties in both appearance and in mechanical properties. Thus the invention also includes polymer powders and articles produced by the described processes.Type: ApplicationFiled: September 27, 2011Publication date: December 5, 2013Applicant: Arkema Inc.Inventors: Christopher A. Bertelo, Manuel A. Garcia-Leiner, Anthony Decarmine, Scott F. Defelice
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Publication number: 20130316145Abstract: The present invention provides processes for the layer-by-layer production of three-dimensional objects using a powder material comprising polyamide PA613 and also to the moldings obtained according to the process.Type: ApplicationFiled: May 8, 2013Publication date: November 28, 2013Inventors: Wolfgang Diekmann, Maik Grebe
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Patent number: 8592519Abstract: Powder compositions and articles and methods of forming articles from powder compositions are provided. In one embodiment the powder compositions include at least one polyester polymer powder and an amount of reinforcing particles having an aspect ratio of preferably at least about 5:1. In another embodiment the powder compositions include at least one medium-high melting temperature, aromatic and crystalline polyester polymer powder. In a preferred embodiment, the powder composition is capable of being formed, via a laser sintering process, into a three-dimensional article that exhibits one or more desirable mechanical properties in an elevated temperature environment.Type: GrantFiled: April 19, 2012Date of Patent: November 26, 2013Assignee: Valspar Sourcing, Inc.Inventor: Raffaele Martinoni
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Patent number: 8591797Abstract: A task often encountered in very recent times is the rapid provision of prototypes. Particularly suitable processes are those based on pulverulent materials and in which the desired structures are produced layer-by-layer through selective melting and solidification. The invention provides the constitution, production and use of a copolyamide powder which was produced using the following monomer units: a) laurolactam or ?-aminoundecanoic acid, and also b) dodecanedioic acid, and either c) decanediamine or dodecanediamine, in shaping processes, and also to moldings produced through a layer-by-layer process which selectively melts regions of a powder layer, using this specific powder. Once the regions previously melted layer-by-layer have been cooled and solidified, the molding can be removed from the powder bed. The moldless layer-by-layer processes for the production of components using the copolyamide powder result in simplified and more reliable conduct of the process and better recyclability.Type: GrantFiled: March 19, 2009Date of Patent: November 26, 2013Assignee: Evonik Degussa GmbHInventors: Sylvia Monsheimer, Maik Grebe, Stefan Altkemper, Sigrid Hessel-Geldmann, Franz-Erich Baumann, Kristiane Warnke, Heike Stemmer, Joachim Muegge, Michael Tuerke, Ulrich Simon
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Publication number: 20130307196Abstract: A process is described for manufacturing articles by selective fusion of polymer powder layers, especially the rapid prototyping by solid-phase laser sintering of a powder based on a copolyamide of type 6 having a low enthalpy of cold crystallization. Further described, are the articles obtained by such a process.Type: ApplicationFiled: December 6, 2011Publication date: November 21, 2013Applicant: Rhodia OperationsInventors: Cécile Corriol, Pierre-Yves Lahary
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Patent number: 8585853Abstract: A layered manufacturing method for forming a desired three-dimensional object by using a powder as a raw material. The method forms a desired solid body, which is employed in a layered manufacturing device, including a stage member having stage surface; a transparent member having an optical window to cover the stage surface to form an enclosed region together with the stage surface; and an exhaust system for exhausting gasses in the enclosed region. The optical window is positioned at a vertical upper direction when the enclosed region is formed.Type: GrantFiled: May 17, 2011Date of Patent: November 19, 2013Inventors: Keijirou Yamamoto, Tsuyoshi Tokunaga
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Publication number: 20130300035Abstract: The invention concerns a method for production of a three-dimensional body by successively providing powder layers and fusing together of selected areas of said layers, which areas correspond to successive cross sections of the three-dimensional body, wherein the method comprises the following steps for at least one of said layers: applying the at least one powder layer onto a working area, and fusing together a selected area of the at least one powder layer by supplying energy from a radiation gun to the selected area.Type: ApplicationFiled: January 28, 2011Publication date: November 14, 2013Applicant: ARCAM ABInventor: Anders Snis
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Patent number: 8568647Abstract: A method of fabricating structural elements on the surface of a component is provided. The structural elements are configured to modify flow of a fluid passing over the surface. Conveniently, the fabrication is performed using a Direct Write technique. A three dimensional element is formed by depositing material on the surface, and subsequently curing the deposited material.Type: GrantFiled: November 6, 2008Date of Patent: October 29, 2013Assignee: BAE Systems PLCInventors: Jagjit Sidhu, Jennifer L McDonald, Sandeep S. P Raja