Plural Heating Steps Including Sintering Patents (Class 419/53)
  • Patent number: 10974321
    Abstract: An additive manufacturing system for building a product includes a base plate for mounting the product thereon, and at least one heating element shaped to at least partially conform to the product and configured to apply heat to at least a portion of the product as the product is additively manufactured to reduce thermal gradients in the product.
    Type: Grant
    Filed: October 11, 2019
    Date of Patent: April 13, 2021
    Assignee: Hamilton Sundstrand Corporation
    Inventor: Eric W. Karlen
  • Patent number: 10953599
    Abstract: According to an example, a printer may include a warming device to apply energy onto a region of a plurality of regions of a layer of build materials. The printer may also include a controller that may calculate, based upon the region upon which the warming device is to apply energy, an energy curve to be applied to the warming device between occurrences of a plurality of events, in which the energy curve defines timings and levels at which the warming device is to be operated between occurrences of the plurality of events. The controller may also control the warming device to be operated to apply energy onto the region according to the calculated energy curve.
    Type: Grant
    Filed: May 12, 2016
    Date of Patent: March 23, 2021
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Xavier Vilajosana, Alejandro Manuel De Pena, Sebastia Cortes I Herms
  • Patent number: 10940533
    Abstract: A system and corresponding method for additive manufacturing of a three-dimensional (3D) object to improve packing density of a powder bed used in the manufacturing process. The system and corresponding method enable higher density packing of the powder. Such higher density packing leads to better mechanical interlocking of particles, leading to lower sintering temperatures and reduced deformation of the 3D object during sintering. An embodiment of the system comprises means for adjusting a volume of a powder metered onto a top surface of the powder bed to produce an adjusted metered volume and means for spreading the adjusted metered volume to produce a smooth volume for forming a smooth layer of the powder with controlled packing density across the top surface of the powder bed. The controlled packing density enables uniform shrinkage, without warping, of the 3D object during sintering to produce higher quality 3D printed objects.
    Type: Grant
    Filed: October 22, 2018
    Date of Patent: March 9, 2021
    Assignee: Desktop Metal, Inc.
    Inventors: George Hudelson, Emanuel M. Sachs, Glenn A. Jordan, Midnight Zero
  • Patent number: 10933583
    Abstract: A method of manufacturing a three-dimensional shaped object in which the three-dimensional shaped object is manufactured by laminating layers includes: a layer formation step of forming layers using a material containing powder and a binder; a removal step of removing a portion of the material in a boundary region including at least one of an end portion of a shaping region of the three-dimensional shaped object in the layer and an outer portion of the shaping region adjacent to the end portion by irradiating the boundary region with a laser; and a melting and solidifying step of melting and solidifying the material after melting in the shaping region by performing irradiation with the laser.
    Type: Grant
    Filed: January 9, 2020
    Date of Patent: March 2, 2021
    Assignee: Seiko Epson Corporation
    Inventors: Takeshi Miyashita, Naoko Shima, Jun Takizawa
  • Patent number: 10919287
    Abstract: In a method for controlling an irradiation system for use in an apparatus for producing a three-dimensional work piece, a first and a second irradiation area as well as an overlap area arranged between the first and the second irradiation area are defined on a surface of a carrier adapted to receive layers of a raw material powder to be irradiated with electromagnetic or particle radiation emitted by the irradiation system. A first irradiation unit of the irradiation system is assigned to the first irradiation area and the overlap area, and a second irradiation unit of the irradiation system is assigned to the second irradiation area and the overlap area. At least one of the first irradiation area, the second irradiation area and the overlap area is defined in dependence on a geometry of the three-dimensional work piece to be produced.
    Type: Grant
    Filed: July 20, 2016
    Date of Patent: February 16, 2021
    Assignee: SLM SOLUTIONS GROUP AG
    Inventors: Andreas Wiesner, Dieter Schwarze, Toni Adam Krol
  • Patent number: 10898954
    Abstract: The present disclosure relates to a method of producing a product through additive manufacturing with heat treatment. The method involves using a fusing beam to melt powder particles disposed on a substrate, where the fusing beam is impressed with a two dimensional pattern containing image information from a first layer to be printed. The fused powder particles are then heat treated with a beam impressed with an additional two dimensional pattern. The additional two dimensional pattern has image information from the first layer to achieve heat treatment of the product. The heat treatment is completed prior to laying down additional new layers of material. The heat treatment is an annealing operation.
    Type: Grant
    Filed: February 19, 2020
    Date of Patent: January 26, 2021
    Assignee: Lawrence Livermore National Security, LLC
    Inventors: James A. Demuth, Andrew J. Bayramian, Bassem S. El-Dasher, Joseph C. Farmer, Kevin J. Kramer, Alexander Rubenchik
  • Patent number: 10888924
    Abstract: A powder processing machine includes a work bed, a powder deposition device operable to deposit powder in the work bed, at least one energy beam device operable to emit an energy beam with a variable beam power and direct the energy beam onto the work bed with a variable beam scan rate to melt and fuse regions of the powder, and a controller operable to dynamically control at least one of the beam power or the beam scan rate to change how the powder melts and fuses. The controller is configured to determine whether an instant set of process parameters falls within a defect condition or a non-defect condition and adjust at least one of the beam power or the beam scan rate responsive to the defect condition such that the instant set of process parameters falls within the non-defect condition.
    Type: Grant
    Filed: January 26, 2018
    Date of Patent: January 12, 2021
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventors: Sergei F. Burlatsky, David Ulrich Furrer, Rebecca L. Runkle, Jesse R. Boyer, Christopher F. O'Neill
  • Patent number: 10885214
    Abstract: Validating additively manufactured components is carried out by transmitting to a distributed validation network printing specification data for a component that is to be additively manufactured, validating the printing specification data, and adding the printing specification data, together with a cryptographically encoded checksum, to a print history log, transmitting the printing specification to a 3D printing device, and implementing a generative manufacturing process for the component that is to be additively manufactured in accordance with the transmitted printing specification data. While the generative manufacturing process is being carried out, in each case following specified manufacturing stages, a plurality of manufacturing parameters prevailing in the preceding manufacturing stage are transmitted to the distributed validation network.
    Type: Grant
    Filed: December 13, 2017
    Date of Patent: January 5, 2021
    Inventors: Claus Gosch, Peter Linde, Matthias Hegenbart
  • Patent number: 10872732
    Abstract: A method for producing an electrical component via a 3D printing includes preparing a first layer which includes a valve metal powder, consolidating at least a portion of the valve metal powder of the first layer via a first selective irradiation with a laser, applying a second layer which includes the valve metal powder to the first layer, consolidating at least a portion of the valve metal powder of the second layer via a second selective irradiation with the laser so as to form a composite of the first layer and of the second layer, applying respective additional layers which include the valve metal powder to the composite, and consolidating at least a portion of the valve metal powder of the respective additional layers via a respective additional selective irradiation with the laser to thereby obtain the electrical component.
    Type: Grant
    Filed: September 4, 2017
    Date of Patent: December 22, 2020
    Assignee: TANIOBIS GMBH
    Inventors: Helmut Haas, Marcel Hagymasi, Kamil Paul Rataj, Christoph Schnitter, Markus Weinmann
  • Patent number: 10800103
    Abstract: An additive manufacturing apparatus includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, and an energy delivery assembly. The energy delivery assembly includes a light source to emit one or more light beams, a first reflective member having a plurality of reflective facets, and at least one second reflective member. The first reflective member is rotatable such that sequential facets sweep the light beam sequentially along a path on the uppermost layer. The at least one second reflective member is movable such that the at least one second reflective surface is repositionable to receive at least one of the at least one light beam and redirect the at least one of at least one light beam along a two-dimensional path on the uppermost layer.
    Type: Grant
    Filed: November 13, 2017
    Date of Patent: October 13, 2020
    Assignee: Applied Materials, Inc.
    Inventors: Hou T. Ng, Nag B. Patibandla, Ajey M. Joshi, Raanan Zehavi, Jeffrey L. Franklin, Kashif Maqsood
  • Patent number: 10799951
    Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize conformal support structures in the process of building objects, as well as novel conformal support structures to be used within these AM processes. The conformal support structures include a first portion that extends from a platform to a concave upward surface of the first portion that is below a downward facing convex surface of the object. The concave upward surface corresponds to the downward facing convex surface. The downward facing convex surface of the object is separated from the concave upward surface of the first portion by at least one portion of unfused powder.
    Type: Grant
    Filed: February 11, 2016
    Date of Patent: October 13, 2020
    Assignee: GENERAL ELECTRIC COMPANY
    Inventor: Daniel Joerger
  • Patent number: 10786865
    Abstract: A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, comprising the steps of: providing at least one model of said three-dimensional article, moving a support structure in z-direction at a predetermined speed while rotating said support structure at a predetermined speed, directing a first and second energy beam causing said powder layer to fuse in first and second selected locations according to said model, wherein a first cover area of said first energy beam on said powder layer is arranged at a predetermined minimum distance and non-overlapping from a second cover area of said second energy beam on said powder layer, a trajectory of said first cover area and a trajectory of said second cover area are at least one of overlapping each other, abutting each other or separated to each other when said support structure is rotated a full lap.
    Type: Grant
    Filed: November 24, 2015
    Date of Patent: September 29, 2020
    Assignee: Arcam AB
    Inventor: Calle Hellestam
  • Patent number: 10751940
    Abstract: According to an example, a recoater for a three-dimensional (3D) printer may include a cylindrical element having a surface to spread build material particles. The build material particles may have a specified average dimension and the surface may include a plurality of depressions that have dimensions that are smaller than the specified average dimension of the build material particles.
    Type: Grant
    Filed: October 27, 2016
    Date of Patent: August 25, 2020
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Haseeb Yusef, William Winters, Jordi Gimenez Manent, Xavier Gasso Puchal, Eduardo Ruiz Martinez, Drew Berwager, Brent Ewald, Micah Aberth
  • Patent number: 10730239
    Abstract: A 3D printer apparatus for printing a refractory materials on the surfaces of workpieces in accordance with a given program is disclosed. The apparatus contains a first generator for generating a first atmospheric ICP beam, a second generator for generating a second atmospheric ICP beam, and a bouncing tube between the generators for breaking clusters of precursor nanoparticles into elementary charged nanoparticles that penetrate in a premelted state into a plasma discharge formed in the second generator under the inductive coupling with a saddle antenna, which encompasses the second generator. The outlet nozzle of the second generator emits the second beam onto an extractor plate that is a part of a plasma gun, which converts the second beam into a finely controlled focusing beam capable of printing a material even on the inner surfaces of deep small diameter gas holes of showerheads.
    Type: Grant
    Filed: November 10, 2019
    Date of Patent: August 4, 2020
    Inventors: Yuri Glukhoy, Tatiana Kerzhner, Anna Ryaboy, Joshua Kerzhner, Michael Ryaboy, Andrew Kerzhner, Kevin Kerzhner
  • Patent number: 10730240
    Abstract: An additive manufacturing apparatus includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, and an energy delivery system. The energy deliver system includes a light source to emit a light beam, and a reflective member having a plurality of reflective facets. The reflective member is positioned in a path of the light beam to receive the light beam and redirect the light beam toward the top surface of the platform to deliver energy to an uppermost layer of the layers of feed material to fuse the feed material. The reflective member is rotatable such that sequential facets sweep the light beam sequentially along a path on the uppermost layer.
    Type: Grant
    Filed: November 13, 2017
    Date of Patent: August 4, 2020
    Assignee: Applied Materials, Inc.
    Inventors: Hou T. Ng, Nag B. Patibandla, Ajey M. Joshi, Raanan Zehavi, Jeffrey L. Franklin, Kashif Maqsood
  • Patent number: 10695865
    Abstract: A controller for use in an additive manufacturing system including at least one laser device configured to generate at least one melt pool in powdered material including a processing device and a memory device. The controller is configured to generate at least one control signal to control a power output of the at least one laser device throughout at least one scan path across the layer of powdered material, the scan path generated at least partially based on a functional relationship between a plurality of points of a generating path and each point of a plurality of points of the scan path. The controller is further configured to generate a non-uniform energy intensity profile for the scan path, and transmit the control signal to the laser device to emit at least one laser beam to generate at least one melt pool.
    Type: Grant
    Filed: March 3, 2017
    Date of Patent: June 30, 2020
    Assignee: General Electric Company
    Inventors: Michael Evans Graham, Lang Yuan
  • Patent number: 10695832
    Abstract: A method for manufacturing a mechanical component by additive manufacturing which includes at least one layering sequence of depositing a powder material and locally melting and resolidifying the powder material. In each layering sequence, a solid layer of solidified material is formed, wherein the solid layers jointly form a solid body. An annealing sequence subsequent to at least one layering sequence includes, locally heating at least a region of the solid body in effecting a local heat input to the immediately beforehand manufactured solid layer which was formed by the immediately precedent layering sequence, with temperature being is maintained below a melting temperature of the material.
    Type: Grant
    Filed: October 6, 2017
    Date of Patent: June 30, 2020
    Assignee: GENERAL ELECTRIC TECHNOLOGY GMBH
    Inventors: Matthias Hoebel, Mikhail Pavlov, Thomas Etter, Roman Engeli
  • Patent number: 10610930
    Abstract: The present invention relates to a methods, computer program products, program elements, and apparatuses for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article. The method comprising the steps of providing at least one electron beam source emitting an electron beam for at least one of heating or fusing the powder material, where the electron beam source comprises a cathode and an anode, and varying an accelerator voltage between the cathode and the anode between at least a first and second predetermined value during the forming of the three-dimensional article.
    Type: Grant
    Filed: November 7, 2016
    Date of Patent: April 7, 2020
    Assignee: Arcam AB
    Inventors: Johan Nordkvist, Ulf Ackelid
  • Patent number: 10576543
    Abstract: A process is provided for manufacturing a part or parts. This manufacturing process includes receiving a plurality of metal materials. The manufacturing process also includes solidifying the metal materials together using an additive manufacturing system to form at least a portion of the part, which comprises an alloy of the metal materials.
    Type: Grant
    Filed: January 22, 2015
    Date of Patent: March 3, 2020
    Assignee: United Technologies Corporation
    Inventors: Aaron T. Nardi, Zissis Dardas
  • Patent number: 10525530
    Abstract: A three-dimensional shaping apparatus includes a shaping table 31, a squeegee 32, a sintering device, a cutting device, transport pathways 4 through which metal powder and fumes that have been discharged to the outer side of a shaping tank 1 after cutting with the cutting device, and metal powder that has been discharged to the outer side of a chamber 2 surrounding the shaping tank 1 without forming part of the laminated layer, are transported to a sifter 5 located at the top of a powder tank 6, and supply devices for inert gas that does not react with the metal powder at an inlet 40 of each transport pathway 4, so as to suppress oxidation of metal powder in the transport pathway for collected metal powder and fumes, and also dust explosion due to sudden oxidation of the same.
    Type: Grant
    Filed: July 26, 2018
    Date of Patent: January 7, 2020
    Assignee: Matsuura Machinery Corp.
    Inventors: Kouichi Amaya, Toshihiko Kato, Tetsushi Midorikawa, Mitsuyoshi Yoshida, Kazuhiro Shimizu
  • Patent number: 10507549
    Abstract: The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.
    Type: Grant
    Filed: February 17, 2017
    Date of Patent: December 17, 2019
    Assignee: VELO3D, INC.
    Inventors: Benyamin Buller, Erel Milshtein, Thai Cheng Chua
  • Patent number: 10335856
    Abstract: An additive manufacturing system includes a platen having a top surface to support an object being manufactured, a dispenser to deliver a plurality of successive layers of precursor material over the platen, a plurality of lamps disposed below the top surface of the platen to heat the platen, and an energy source to fuse at least some of the outermost layer of precursor material.
    Type: Grant
    Filed: June 28, 2016
    Date of Patent: July 2, 2019
    Assignee: Applied Materials, Inc.
    Inventors: Bharath Swaminathan, Eric Ng, Nag B. Patibandla, Hou T. Ng, Ashavani Kumar, Ajey M. Joshi, Bernard Frey, Kasiraman Krishnan
  • Patent number: 10338569
    Abstract: A computerized method, system, program product and additive manufacturing (AM) system are disclosed. Embodiments provide for modifying object code representative of an object to be physically generated layer by layer by a computerized AM system using the object code. The computerized method may include providing an interface to allow a user to manually: select a region within the object in the object code, the object code including a plurality of pre-assigned build strategy parameters for the object that control operation of the computerized AM system, and selectively modify a build strategy parameter in the selected region in the object code to change an operation of the computerized AM system from the plurality of pre-assigned build strategy parameters during building of the object by the computerized AM system.
    Type: Grant
    Filed: August 15, 2017
    Date of Patent: July 2, 2019
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Donnell Eugene Crear, Michael Evans Graham, Tao Jia, Mohammed Mounir Shalaby
  • Patent number: 10259042
    Abstract: The invention relates to a device for the manufacture or repair of a three-dimensional object, comprising at least one construction chamber for a successive solidification of at least one solidifiable material layer by layer in predefined regions for layer-by-layer buildup of the three-dimensional object or for layer-by-layer repair of individual regions of the three-dimensional object inside of the construction chamber, at least one coater that can travel for deposition of the material on at least one buildup and joining zone of a construction platform formed in the construction chamber, at least one inflow nozzle and at least one suction outlet nozzle for a process gas, with the inflow nozzle and the outlet nozzle being arranged in such a way that a gas flow that passes at least partially above the buildup and joining zone is created, and at least one overflow tank.
    Type: Grant
    Filed: January 22, 2016
    Date of Patent: April 16, 2019
    Assignee: MTU Aero Engines AG
    Inventor: Maximilian Fisser
  • Patent number: 10183444
    Abstract: A three-dimensional object printing module has been developed. The printing module includes a first processing station configured to perform an operation. The printing module further includes a track configured to guide a cart moved by a motive force in a first direction to the first processing station and to guide the cart moved by the motive force in the first direction from the first processing station. The printing module further includes at least one lead screw disposed parallel to the first direction along the track at the first processing station and configured to engage the cart at the first processing station. The printing module further includes an actuator operatively connected to the at least one lead screw and configured to rotate the lead screw bi-directionally about a longitudinal axis of the lead screw to enable the cart to move along the track at the processing station without the motive force.
    Type: Grant
    Filed: April 22, 2015
    Date of Patent: January 22, 2019
    Assignee: Xerox Corporation
    Inventor: Richard A. Campbell
  • Patent number: 10144063
    Abstract: A method for detecting defects in three-dimensional articles. Providing a model of said article. Providing a first powder layer on a substrate, directing an energy beam over said substrate causing said first powder layer to fuse in selected locations forming a first cross section of said three-dimensional article, providing a second powder layer on said substrate, directing the energy beam over said substrate causing said second powder layer to fuse in selected locations to form a second cross section of said three-dimensional article. A first and second image of a first and second fusion zone of said first powder layer respectively is captured. Comparing said first and second images with corresponding layers in said model. Detecting a defect in the three-dimensional article if a deviation in said first image with respect to said model is at least partially overlapping a deviation in said second image with respect to said model.
    Type: Grant
    Filed: December 5, 2012
    Date of Patent: December 4, 2018
    Assignee: ARCAM AB
    Inventor: Ulric Ljungblad
  • Patent number: 10071422
    Abstract: The present disclosure various apparatuses, and systems for 3D printing. The present disclosure provides three-dimensional (3D) printing methods, apparatuses, software and systems for a step and repeat energy irradiation process; controlling material characteristics and/or deformation of the 3D object; reducing deformation in a printed 3D object; and planarizing a material bed.
    Type: Grant
    Filed: December 9, 2016
    Date of Patent: September 11, 2018
    Assignee: VELO3D, INC.
    Inventors: Benyamin Buller, Erel Milshtein, Thomas Blasius Brezoczky, Zachary Ryan Murphree, Daniel Christiansen, Alan Rick Lappen
  • Publication number: 20150136908
    Abstract: A manufacturing method for passenger door corner components of aircraft or spacecraft includes using additive layer manufacturing, ALM, to form an integral passenger door corner component. The integral passenger door corner component includes a substantially cruciform shape having a frame coupling member with two frame couplings as end pieces. The frame coupling member intersect with a beam coupling member with two beam couplings as end pieces.
    Type: Application
    Filed: November 10, 2014
    Publication date: May 21, 2015
    Applicant: Airbus Operations GmbH
    Inventors: Matthias Hegenbart, Wolfgang Eilken
  • Publication number: 20150141234
    Abstract: A manufacturing method for reinforced structural elements includes providing a reinforcement structure including a first material, and embedding the reinforcement structure in an encasing matrix comprising a second material using additive layer manufacturing, ALM. A manufacturing tool for reinforced structural elements includes a positioning component including a jig for clamping a reinforcement structure including a first material and an ALM robot configured to embed a reinforcement structure clamped in the jig in an encasing matrix including a second material.
    Type: Application
    Filed: November 10, 2014
    Publication date: May 21, 2015
    Applicant: Airbus Operations GmbH
    Inventors: Peter Sander, Matthias Hegenbart, Carlos Weinbuch, Helene-Hedwig Koenig
  • Patent number: 9028582
    Abstract: Seizure resistance and wear resistance of Cu—Bi—In copper-alloy sliding material are enhanced by forming a soft phase of as pure as possible Bi. Mixed powder of Cu—In cuprous alloy powder and Cu—Bi containing Cu-based alloy powder is used. A sintering condition is set such that Bi moves outside particles of said Cu—Bi containing Cu-based powder and forms a Bi grain-boundary phase free of In, and In diffuses from said Cu—In containing Cu-based powder to said Cu—Bi containing Cu-based powder.
    Type: Grant
    Filed: January 22, 2009
    Date of Patent: May 12, 2015
    Assignee: Taiho Kogyo Co., Ltd.
    Inventors: Hitoshi Wada, Takashi Tomikawa, Daisuke Yoshitome, Hiromi Yokota
  • Publication number: 20150125657
    Abstract: The invention relates to a method for manufacturing road surface covering elements that can be mounted on rollers of chassis dynamometers, including detection of a surface contour of a road surface covering within an essentially strip-shaped section. The method also includes production of a digital image of the detected section and manufacturing of the road surface covering element according to the digital image by means of a three-dimensional manufacturing technique.
    Type: Application
    Filed: April 11, 2013
    Publication date: May 7, 2015
    Inventors: Anton Knestel, Christian Hartmann, Thomas Becherer
  • Publication number: 20150113993
    Abstract: A fuel injector assembly includes a fuel injector and a fuel injector shroud housing the fuel injector. The fuel injector includes a body and a nozzle coupled to the body. The fuel injector shroud includes a swirler device defining a center opening proximate to the nozzle of the fuel injector and a plurality of swirler holes surrounding the center opening, a body section with an air inlet configured to admit a flow of air into the fuel injector shroud and a dome section defining a mount for securing the swirler device to the body section, and at least one interior rib positioned on an interior surface of the dome section configured to direct the flow of air to the swirler holes of the swirler device such that the flow of air exiting through the swirler is mixed with the flow of fuel exiting the nozzle.
    Type: Application
    Filed: October 30, 2013
    Publication date: April 30, 2015
    Inventors: Nagaraja S. Rudrapatna, Thomas J. Bronson, Donald G. Godfrey
  • Publication number: 20150090074
    Abstract: The invention refers to a method for manufacturing a three-dimensional metallic article/component made of a Ni-, Co-, Fe-based superalloy or combinations thereof, entirely or partly, by a powder based additive manufacturing process. During the step of performing powder melting by scanning a dual laser setup is used, where two laser beams of different beam properties are combined in the same machine and by adjusted beam profiling and integration of a suitable beam switch in a controlled manner a switching between two different laser beam diameters is performed. In each layer the laser beam with the smaller diameter scans the whole area and in every kth layer, with k>1, the laser beam with the larger diameter scans the area where a coarse grain size is needed thereby remelting the area with fine grain sizes. With such a manufacturing method higher lifetime and operation performances of metallic parts and prototypes can be reached.
    Type: Application
    Filed: September 25, 2014
    Publication date: April 2, 2015
    Inventors: Thomas ETTER, Matthias HOEBEL, Julius SCHURB, Felix ROERIG
  • Patent number: 8992828
    Abstract: A method for manufacturing a high ductility Ti-, Ti-alloy or NiTi-foam, meaning a compression strain higher than 10%, includes: preparing a powder suspension of a Ti-, NiTi- or Ti-alloy powder, bringing the said powder suspension into a desired form by gelcasting to form a green artifact. The method also includes a calcination step wherein the green artifact is calcined, and sintering the artifact. The calcination step includes a slow heating step wherein said green artifact is heated at a rate lower or equal to 20° C./hour to a temperature between 400° C. and 600° C. and the Ti-, NiTi- or Ti-alloy powder has a particle size less than 100 ?m. A high ductility Ti-, Ti-alloy or NiTi foam, with a compression higher than 10%, with a theoretical density less than 30%, pore size (cell size) between 50 to 1000 ?m can be obtained with such a method.
    Type: Grant
    Filed: June 7, 2006
    Date of Patent: March 31, 2015
    Assignee: Vlaamse Instelling Voor Technologisch Onderzoek (VITO)
    Inventors: Steven Mullens, Ivo Thijs, Jozef Cooymans, Jan Luyten
  • Publication number: 20150064048
    Abstract: Method for fabricating a three-dimensional object by successive consolidation, layer by layer, of selected regions of a layer of powder, consolidated regions corresponding to successive sections of the three-dimensional object, comprising in order: a—deposit layer of powder onto a support; b—fuse the layer of powder by a first laser energy source so as to obtain a fused layer corresponding to the section of the object and exhibiting a first state of its mechanical properties, c—heat at least a part of the fused layer by a second electron beam energy source to a temperature which follows a controlled variation over time so as to modify the first state of the fused layer and to obtain a consolidated layer with improved mechanical properties, d—repeat the preceding steps until several superposed consolidated layers are formed with improved properties forming the object.
    Type: Application
    Filed: February 19, 2013
    Publication date: March 5, 2015
    Inventors: Christophe Bessac, Stephanie Brochet, Frederic Pialot, Gilles Walrand
  • Publication number: 20150060042
    Abstract: An electric submersible pump and pump system including additively manufactures structures and method of manufacture are disclosed. The pump system including the electric submersible pump and an electric motor configured to operate the electric submersible pump. The electric submersible pump including a housing, at least one impeller and at least one diffuser disposed within the housing in cooperative engagement. The housing, the at least one impeller, and the at least one diffuser defining an internal volume configured to receive a fluid. At least one of the at least one impeller and the at least one diffuser configured as a monolithic additively manufactured structure comprised of a metal matrix composite. Also provided is an electric submersible pump including an impeller and a diffuser, wherein at least one of the impeller and the diffuser is configured as a monolithic additively manufactured structure comprised of a tungsten carbide (WC) dispersed in a metal matrix.
    Type: Application
    Filed: August 29, 2013
    Publication date: March 5, 2015
    Applicant: General Electric Company
    Inventors: Vijay Shilpiekandula, James William Sears, Yanzhe Yang, Hongqing Sun, Farshad Ghasripoor
  • Publication number: 20150064050
    Abstract: A device for additive manufacturing of components by selective irradiation of a powder bed, having a processing chamber -in which at least one powder bed chamber and at least one radiation source are arranged such that the radiation source can irradiate a powder in the powder bed chamber, and wherein the device includes at least one induction coil, so that a component which is produced by irradiation of the powder bed can be at least partially inductively heated, and wherein the induction coil is movable relative to one or more powder bed chambers. A method for additive manufacturing of components by selective irradiation of a powder bed, in which method the component being manufactured is inductively heated at the same time, wherein the position of one or more induction coils for inductive heating is determined and adjusted based on the geometry of the component to be produced.
    Type: Application
    Filed: March 28, 2013
    Publication date: March 5, 2015
    Applicant: MTU Aero Engines AG
    Inventors: Ulrich Retze, Andreas Jakimov, Herbert Hanrieder
  • Publication number: 20150048209
    Abstract: A structural spacecraft component comprising internal microstructure; wherein said microstructure comprises a plurality of parallel layers and a plurality of spacers that connect adjacent parallel layers; wherein said structural spacecraft component is a product of an additive manufacturing process.
    Type: Application
    Filed: August 18, 2014
    Publication date: February 19, 2015
    Inventors: Robert Hoyt, Jonathan Wrobel, Jesse Cushing, Mark Jaster, Nestor Voronka, Scott Frank, Jeffrey Slostad, Leonid Paritsky
  • Patent number: 8951465
    Abstract: A method for preparing an implant having a porous metal component. A loose powder mixture including a biocompatible metal powder and a spacing agent is prepared and compressed onto a metal base. After being compressed, the spacing agent is removed, thereby forming a compact including a porous metal structure pressed on the metal base. The compact is sintered, forming a subassembly, which is aligned with a metal substrate portion of an implant. A metallurgical bonding process, such as diffusion bonding, is performed at the interface of the subassembly and the metal substrate to form an implant having a porous metal component.
    Type: Grant
    Filed: February 25, 2013
    Date of Patent: February 10, 2015
    Assignee: Biomet Manufacturing, LLC
    Inventor: Gautam Gupta
  • Publication number: 20150024233
    Abstract: Methods and apparatuses to fabricate additive manufactured parts with in-process monitoring are described. As parts are formed layer-by-layer, a 3D measurement of each layer or layer group may be acquired. The acquisition of dimensional data may be performed at least partially in parallel with the formation of layers. The dimensional data may be accumulated until the part is fully formed, resulting in a part that was completely inspected as it was built. The as-built measurement data may be compared to the input geometrical description of the desired part shape. Where the part fails to meet tolerance, it may be amended during the build process or rejected.
    Type: Application
    Filed: July 19, 2013
    Publication date: January 22, 2015
    Applicant: The Boeing Company
    Inventor: Steven Matthew GUNTHER
  • Publication number: 20150017055
    Abstract: A manufacturing method of a three-dimensional shaped object is capable of suitably forming a solidified layer by subsequent formation of a powder layer. The manufacturing method according to an embodiment of the present invention is performed by repetition of a powder-layer forming and a solidified-layer forming, the repetition including forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a light-beam condition for an irradiation path with an unirradiated portion on both adjacent sides thereof is different from that for another irradiation path with an irradiated portion at an adjacent region.
    Type: Application
    Filed: March 6, 2013
    Publication date: January 15, 2015
    Applicant: PANASONIC CORPORATION
    Inventors: Satoshi Abe, Norio Yoshida, Yoshikazu Higashi
  • Publication number: 20150018956
    Abstract: A surgical implant device, comprising: a body portion; and one or more surfaces comprising a plurality of protruding structures; wherein the body portion and the one or more surfaces comprising the plurality of protruding structures are integrally formed. The one or more surfaces comprising the plurality of protruding structures are formed by an additive manufacturing process. The plurality of protruding structures comprise a plurality of needles. Optionally, the surgical implant device comprises one of an anterior lumbar interbody fusion cage, a posterior lumbar interbody fusion cage, a transforaminal lumbar interbody fusion cage, an oblique lumbar interbody fusion cage, a cervical cage, and a bone screw.
    Type: Application
    Filed: July 24, 2014
    Publication date: January 15, 2015
    Inventors: John C. STEINMANN, Scott RUCKER, Tim RASMUSSEN, John P. STEINMANN, Trace CAWLEY, Thomas ROSS, Ernesto RIOS, Andrew OLCESE
  • Publication number: 20150017054
    Abstract: Disclosed is a method for generatively producing components by layer-by-layer building from a powder material by selective material bonding of powder particles by a high-energy beam. An eddy current testing is carried out concurrently with the material bonding. Also disclosed is an apparatus which is suitable for carrying out the method.
    Type: Application
    Filed: July 8, 2014
    Publication date: January 15, 2015
    Inventors: Andreas JAKIMOV, Georg SCHLICK, Joachim BAMBERG, Thomas HESS
  • Publication number: 20150004046
    Abstract: A system for fabricating a component includes an additive manufacturing device and a computing device. The additive manufacturing device is configured to fabricate a first component by sequentially forming a plurality of superposed layers based upon a nominal digital representation of a second component, which includes a plurality of nominal digital two-dimensional cross-sections, each corresponding to a layer of the first component.
    Type: Application
    Filed: June 28, 2013
    Publication date: January 1, 2015
    Inventors: Michael Evans Graham, William Thomas Carter, Mark Allen Cheverton, Pinghai Yang
  • Publication number: 20140363327
    Abstract: A method for forming a component includes providing a first layer of a mixture of first and second powders. The method includes determining the frequency of an alternating magnetic field to induce eddy currents sufficient to bulk heat only one of the first and second powders. The alternating magnetic field is applied at the determined frequency to a portion of the first layer of the mixture using a flux concentrator. Exposure to the magnetic field changes the phase of at least a portion of the first powder to liquid. The liquid portion couples to at least some of the second powder and subsequently solidifies to provide a composite component.
    Type: Application
    Filed: June 10, 2014
    Publication date: December 11, 2014
    Inventor: Matthew J. Holcomb
  • Publication number: 20140348691
    Abstract: A method for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, said method comprising the steps of: providing a model of said three dimensional article, providing a first powder layer on a work table, directing a first energy beam from a first energy beam source over said work table causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, directing a second energy beam from a second energy beam source over said work table causing said first powder layer to fuse in second selected locations according to said model to form the first cross section of said three-dimensional article, wherein said first and second locations of said first powder layer are at least partially overlapping each other.
    Type: Application
    Filed: April 3, 2014
    Publication date: November 27, 2014
    Applicant: ARCAM AB
    Inventors: Ulric Ljungblad, Anders Snis
  • Publication number: 20140348692
    Abstract: An apparatus and a process for manufacturing a three-dimensional object by successive layer-by-layer consolidation of selected zones of a powder stratum, the consolidated zones corresponding to successive sections of the three-dimensional object, each layer being divided into a central internal portion and an external border , said process comprising the following steps in order: a—depositing a powder layer on a holder; b—fusing the external border of said powder layer by means of a laser beam originating from a first energy source by moving the laser beam of said first energy source relative to the object along a preset path that follows the contour of said external border corresponding to the contour of the cross section of the object so as to selectively fuse said layer; and c—fusing the central internal portion of the powder layer by means of an electron beam originating from a second energy source, by moving the electron beam of said second energy source relative to the object so as to sweep it over s
    Type: Application
    Filed: December 21, 2012
    Publication date: November 27, 2014
    Applicants: COMPAGNIE GENERALE DES ESTABLISSEMENTS MICHELIN, MICHELIN RECHERCHE ET TECHNIQUE S.A.
    Inventors: Christophe Bessac, Frédéric Pialot, Gilles Walrand
  • Publication number: 20140308153
    Abstract: A method for detecting defects in three-dimensional articles. Providing a model of said article. Providing a first powder layer on a substrate, directing an energy beam over said substrate causing said first powder layer to fuse in selected locations forming a first cross section of said three-dimensional article, providing a second powder layer on said substrate, directing the energy beam over said substrate causing said second powder layer to fuse in selected locations to form a second cross section of said three-dimensional article. A first and second image of a first and second fusion zone of said first powder layer respectively is captured. Comparing said first and second images with corresponding layers in said model. Detecting a defect in the three-dimensional article if a deviation in said first image with respect to said model is at least partially overlapping a deviation in said second image with respect to said model.
    Type: Application
    Filed: December 5, 2012
    Publication date: October 16, 2014
    Inventor: Ulric Ljungblad
  • Patent number: 8852498
    Abstract: A process for fabricating hollow metal shells such as Be or Al filled with a selected gas such as D or T. An organic preform is coated with a slurry of organic binder and metal powder of Be or Al. The coated preform is heated to remove the preform and any organics to form a hollow shell which is then fired at an elevated temperature in a gas so as to seal the shell and capture the gas inside the sealed shell.
    Type: Grant
    Filed: April 20, 2012
    Date of Patent: October 7, 2014
    Assignee: Imaging Systems Technology, Inc.
    Inventor: Carol Ann Wedding
  • Patent number: 8840832
    Abstract: Material processing systems are disclosed. Some systems include methods of eliminating or reducing defects in elongate workpieces that can undergo large deformations during processing. Some systems include apparatus configured to facilitate such large deformations while maintaining internal stresses (e.g., tensile stresses) below a threshold stress. Some disclosed systems pertain to powder extrusion techniques. Continuous and batch processing systems are disclosed.
    Type: Grant
    Filed: March 2, 2011
    Date of Patent: September 23, 2014
    Assignee: Accellent Inc.
    Inventors: Mark W. Broadley, James Alan Sago, John Eckert, Jeffrey M. Farina