Plural Heating Steps Including Sintering Patents (Class 419/53)
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Patent number: 12134483Abstract: A system for automated surface anomaly detection includes at least one processor which is configured to retrieve from non-volatile memory a 3D control image; capture a 3D target image depicting at least the portion of the exterior of a target object; generate 2D target planar images of the target object based on the 3D target image, using a first plurality of virtual cameras; generate 2D control planar images of the control object based on the 3D control image using a second plurality of virtual cameras, the 2D control planar images corresponding to the 2D target planar images of the target object; detect at least one difference between the 2D target planar images and the 2D control planar images; and generate and cause to be displayed an output image comprising a depiction of the target object with the at least one difference indicated.Type: GrantFiled: March 7, 2022Date of Patent: November 5, 2024Assignee: The Boeing CompanyInventors: Amir Afrasiabi, Zachary Ryan Smith
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Patent number: 12036730Abstract: 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: GrantFiled: September 2, 2020Date of Patent: July 16, 2024Assignee: ARCAM ABInventor: Calle Hellestam
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Patent number: 11958982Abstract: A materials kit for three-dimensional (3D) printing can include a powder bed material including electroactive polymer particles including electroactive polymer having a melting temperature from about 100° C. to about 250° C. and a fusing agent including a radiation absorber to selectively apply to the powder bed material.Type: GrantFiled: January 16, 2019Date of Patent: April 16, 2024Assignee: Hewlett-Packard Development Company, L.P.Inventors: James William Stasiak, Garry Hinch, Stanley J. Kozmiski
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Patent number: 11850661Abstract: Disclosed is a method for providing control data for an additive manufacturing device. The method includes accessing computer-based model data of a section of the object to be manufactured, defining a first portion and an adjoining second portion within the object section, and producing a data model of a region of a layer of the object section. Within the region a first portion cross-section cuts through the first portion and a second portion cross-section cuts through the second portion. An energy input parameter in the data model has, on average, a different value in the first portion cross-section than in the second portion cross-section and the energy beam is moved over the boundary of the first and second portion. Control data corresponding to the data model is provided for the generation of a control data set for the additive manufacturing device.Type: GrantFiled: August 2, 2018Date of Patent: December 26, 2023Assignee: EOS GmbH Electro Optical SystemsInventors: Michael Göth, Ludger Hümmeler, Alexander Bockstaller
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Patent number: 11752690Abstract: The purpose of the present invention is to provide a resin composition for forming three-dimensionally shaped objects having high dimensional accuracy. In order to achieve the purpose, the resin composition is used in a three-dimensional shaping method wherein either forming a thin layer that comprises a particulate resin composition and selectively irradiating the thin layer with laser light are repeated or melt-extruding a resin composition into a filament shape and forming a layer of the filament-shaped extruded resin composition are repeated, thereby forming a three-dimensionally shaped object. The resin composition has a particulate or filament shape, comprises polysaccharide nanofibers and a resin, and has a content of the polysaccharide nanofibers of 1-70 mass %. In the resin composition, the maximum value of loss modulus at temperatures in the range of (melting temperature)±20° C. is 10-1,000 times the minimum value of loss modulus at temperatures in the range of (melting temperature)±20° C.Type: GrantFiled: December 8, 2017Date of Patent: September 12, 2023Assignee: KONICA MINOLTA, INC.Inventor: Keisuke Mizoguchi
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Patent number: 11717891Abstract: There is provided a method for producing a metallic workpiece in layers by additive manufacturing, metallurgical layers of the workpiece being produced by providing a metal material in a manufacturing chamber for each metallurgical layer and applying a laser beam to the metal material, and providing a gas atmosphere in the manufacturing chamber during the application of the laser beam to the layers of the metal material, wherein a part of the gas atmosphere is drawn off from the manufacturing chamber as a gas stream, at least one parameter of the gas stream and/or the gas atmosphere being determined and being compared with a desired value. Depending on the comparison of the parameter with the desired value, the gas stream is fed back to the manufacturing chamber and a process gas is supplied to the manufacturing chamber.Type: GrantFiled: March 23, 2016Date of Patent: August 8, 2023Assignee: Messer Industries USA, Inc.Inventor: Pierre Foret
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Patent number: 11668360Abstract: A hybrid torque bar for a brake assembly may comprise a base portion, a pin extending from a first end of the base portion, and a rail extending between the first end of the base portion and a second end of the base portion opposite the first end. The base portion may be formed using a first manufacturing process. At least one of the pin or the rail may be formed using a second manufacturing process. The second manufacturing process may comprise an additive manufacturing technique.Type: GrantFiled: July 8, 2021Date of Patent: June 6, 2023Assignee: Goodrich CorporationInventors: Leslie Steele, Thomas P. Filburn, Michael A. Klecka
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Patent number: 11666969Abstract: A 3D printing device for producing a three-dimensional component form at least two different materials. The 3D printing device has both a spray-printing unit and an electron-beam and/or laser unit. To produce the three-dimensional component, the spray-printing unit is designed and set up to spray the at least two different materials, and the electron-beam and/or laser unit is designed and set up to join sprayed-on material integrally by fusing by means of an electron beam and/or by means of a laser beam of the electron-beam and/or laser unit.Type: GrantFiled: November 7, 2017Date of Patent: June 6, 2023Inventor: Stefan Beetz
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Patent number: 11536671Abstract: An additive manufacturing system comprises an apparatus arranged to distribute layer of metallic powder across a build plane and a power source arranged to emit a beam of energy at the build plane and fuse the metallic powder into a portion of a part. The system includes a processor configured to steer the beam of energy across the build plane and receive data generated by one or more sensors that detect electromagnetic energy emitted from the build plane when the beam of energy fuses the metallic powder. The received data is converted into one or more parameters that indicate one or more conditions at the build plane while the beam of energy fuses the metallic powder. The one or more parameters are used as input into a machine learning algorithm to detect one or more defects in the fused metallic powder.Type: GrantFiled: July 30, 2021Date of Patent: December 27, 2022Assignee: SIGMA LABS, INC.Inventors: Darren Beckett, Roger Frye, Christina Xuan Yu, Scott Betts, Lars Jacquemetton, Kevin C. Anderson
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Patent number: 11511351Abstract: An additive manufacturing apparatus includes a powder layer forming portion, an energy beam source, and a contact detection sensor including a plate-like probe. The powder layer forming portion is configured to form a powder layer in a predetermined region. The energy beam source is configured to radiate an energy beam to the powder layer formed by the powder layer forming portion to fuse or sinter the powder layer so that a solidified layer is formed. Presence or absence of a projection portion on a surface of the solidified layer is detected by using the contact detection sensor.Type: GrantFiled: July 19, 2019Date of Patent: November 29, 2022Assignee: CANON KABUSHIKI KAISHAInventors: Koji Kitani, Naoki Takizawa
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Patent number: 11511485Abstract: A method of manufacturing a three-dimensional (3D) object may include fabricating a support structure and fabricating the 3D object on the support structure, wherein the support structure contacts the 3D object at a support region of the 3D object. The method further includes overcuring the 3D object at an overcure region of the 3D object, wherein the overcure region is distinct from the support region, and removing the support structure from the 3D object. After removal of the support structure, a support mark remains on the 3D printed object where the support structure had contacted the 3D object, wherein the overcure region of the 3D object projects past the support mark.Type: GrantFiled: April 1, 2020Date of Patent: November 29, 2022Assignee: Align Technology, Inc.Inventors: Mehdi Mojdeh, Brett E. Kelly, Shiva P. Sambu
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Patent number: 11446741Abstract: A method is disclosed for manufacturing a part via an additive manufacturing process. A solution is used which has a volatile component within which is suspended particles of a powdered material. The solution is heated until it at least one of begins boiling or is about to begin boiling. The heated solution is then deposited at least at one location on a substrate to help form a layer of the part. The volatile component then evaporates, leaving only the particles of powdered material. The particles are then heated to the melting point. The deposition and heating operations are repeated to successively form a plurality of layers for the part. The evaporation of the volatile component helps to cool the part.Type: GrantFiled: August 10, 2020Date of Patent: September 20, 2022Assignee: Lawrence Livermore National Security, LLCInventors: James A. Demuth, Andrew J. Bayramian, Bassem S. El-Dasher, Kevin J. Kramer
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Patent number: 11440255Abstract: A system for additive manufacturing under generated force includes a mechanical arm, a build platform, a build platform controller, a material delivery system controller, a laser scan system, a laser scan system controller, a motor controller and a master controller. The master controller determines a location of the material delivered to the build platform. The master controller further calculates a rate of rotation of the build platform as a function of the location of the material delivered and a desired centrifugal acceleration. The master controller further calculates an adjustment factor to correlate a rotation of the laser scan system to a rotation of the mechanical arm as a function of the location of the material delivered and a calculated rate of rotation of the build platform.Type: GrantFiled: September 16, 2019Date of Patent: September 13, 2022Assignee: MRI. Materials Resources LLCInventors: Ayman A. Salem, Daniel P. Satko
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Patent number: 11421119Abstract: The purpose of the present invention is to provide a liquid resin composition which includes polysaccharide nanofibres, and which is used in a three-dimensional moulding production method in which a moulding obtained by curing the resin composition by irradiating the resin composition with active energy rays is three-dimensionally formed, wherein unevenness in strength in the height direction is not readily produced in the formed three-dimensional moulding. The present invention relates to a liquid resin composition which is used to produce a three-dimensional moulding, and which three-dimensionally forms a moulding as a result of being cured by being selectively irradiated with active energy rays. The resin composition includes an active energy ray-curable compound and polysaccharide nanofibres. The ratio of the number of polysaccharide nanofibres having a branched structure to the total number of polysaccharide nanofibres is less than 20%.Type: GrantFiled: December 5, 2017Date of Patent: August 23, 2022Assignee: KONICA MINOLTA, INC.Inventor: Takeshi Kojima
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Patent number: 11407035Abstract: An additive manufacturing machine for repairing a component includes a build platform that supports the component and a powder dispensing assembly for selectively depositing additive powder over the build platform. A powder seal assembly includes a powder support plate positioned above the build platform and defining an aperture for receiving the component without contacting the component. An inflatable sealing element is operably coupled to the powder support plate around the aperture and is inflated to contact and seal against the component, thereby forming a support surface above the build platform upon which additive powder may be deposited.Type: GrantFiled: January 30, 2019Date of Patent: August 9, 2022Assignee: GENERAL ELECTRIC COMPANYInventors: Jinjie Shi, Scott Mitchel Lowe, Matthew Scott Langford, Jolene Ranae Grethel
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Patent number: 11376789Abstract: A three-dimensional printing apparatus for manufacturing a three-dimensional object includes a controller and a three-dimensional printer. The controller has a signal generator. The three-dimensional printer includes a print head, a part carrier, and a plasma field applicator. The plasma field applicator is disposed on an end of the print head. The controller is in communication with the print head, part carrier, and plasma field applicator. The three dimensional printer builds the three-dimensional object onto the part carrier. The signal generator outputs a signal to the plasma field applicator and the plasma field applicator generates an electromagnetic field and induced current pathway incident to the three-dimensional object on the part carrier.Type: GrantFiled: May 18, 2018Date of Patent: July 5, 2022Assignee: Essentium, Inc.Inventors: Charles Brandon Sweeney, Travis Eubanks, Alex Stockton, Blake Teipel
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Patent number: 11351612Abstract: An additive manufacturing method for a part includes forming a pillar by fusing metallic material to form a hollow body portion including a wall having an inner surface and an outer surface and fusing metallic material to form a cap portion extending from a distal end of the body portion. The method includes forming the pillar by fusing metallic material to form a distal portion supported on the cap portion, supporting at least a portion of the part by the pillar, and removing the pillar from the part.Type: GrantFiled: May 22, 2019Date of Patent: June 7, 2022Assignee: Caterpillar Inc.Inventors: Kevin L. Martin, Thierry A. Marchione
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Patent number: 11325312Abstract: There is disclosed a build material supply unit, comprising: a supply chamber body enclosing a supply volume to contain a build material for additive manufacture; an electromagnetic distance sensor to determine a length parameter relating to a length of a beam pathway extending from an emitter of the sensor to a surface level of build material in the supply volume; and a reflector to reflect the beam pathway between the emitter and the surface level of build material; wherein the reflector is spaced apart from the emitter.Type: GrantFiled: March 24, 2016Date of Patent: May 10, 2022Assignee: Hewlett-Packard Development Company, L.P.Inventors: Miguel Angel Lopez, Pau Martin Vidal, Carlos Perez, Anna Torrent, Guillermo Garcia Marcos, Marius Valles, Albert Mora Murciano
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Patent number: 11173545Abstract: The present disclosure relates to a method for forming a three dimensional, hierarchical, porous metal structure with deterministically controlled 3D multiscale pore architectures. The method may involve providing a feedstock able to be applied in an additive manufacturing process, and using an additive manufacturing process to produce a three dimensional (3D) structure using the feedstock. The method may involve further processing the 3D structure through at least a de-alloying operation to form a metallic 3D structure having an engineered, digitally controlled macropore morphology with integrated nanoporosity.Type: GrantFiled: October 23, 2017Date of Patent: November 16, 2021Assignee: Lawrence Livermore National Security, LLCInventors: Zhen Qi, Juergen Biener, Wen Chen, Eric Duoss, Christopher Spadaccini, Marcus A. Worsley, Jianchao Ye, Cheng Zhu
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Patent number: 11123932Abstract: A system may include a processor configured to receive toolpaths along which a 3D printer deposits beads of material in a plurality of layers in order to additively build up a product. Based on the toolpaths, the processor may determine an image for each layer and may process the images based on a default bead size to determine a bead size image for each layer comprised of pixels having values that specify bead size for locations along the toolpaths. The image processing produces pixel values for the bead size images that vary in magnitude at different locations along the toolpaths in order to represent smaller and larger bead sizes relative to the default bead size, which smaller and larger bead sizes respectively minimize over-depositing and under-depositing of material by the 3D printer that would otherwise occur with the default bead size.Type: GrantFiled: September 26, 2017Date of Patent: September 21, 2021Assignee: Siemens Industry Software Inc.Inventors: Prakhar Jaiswal, Suraj Ravi Musuvathy, Erhan Arisoy, David Madeley
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Patent number: 11123798Abstract: A method for manufacturing a three-dimensional semi-finished product comprises the steps of applying a first raw material powder to a carrier, applying a second raw material powder to the carrier, selectively irradiating the first raw material powder applied to the carrier with electromagnetic radiation or particle radiation, in order to manufacture a workpiece produced from the first raw material powder on the carrier by a generative layer construction method, and selectively irradiating the second raw material powder applied to the carrier with electromagnetic radiation or particle radiation, in order to manufacture a support element produced from the second raw material powder on the carrier by a generative layer construction method, wherein the support element produced from the second raw material powder has a higher thermal conductivity than the workpiece produced from the first raw material powder and wherein the support element dissipates heat introduced during the irradiation of the first and the secoType: GrantFiled: November 13, 2018Date of Patent: September 21, 2021Assignee: SLM Solutions Group AGInventor: Dieter Schwarze
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Patent number: 11090728Abstract: Apparatus for additive manufacturing includes:—a platform adapted to receive a powder bed that is laid thereon; —a laser source adapted to emit a laser beam towards the powder bed; —a first doctor blade and a second doctor blade opposite to the first doctor blade and located at a predetermined distance from said first doctor blade, the doctor blades being adapted to move in the same direction (X), so as to slide along the whole platform and define a work area, into which the laser beam is directed in order to manufacture a product; wherein the powder bed (102) is laid out by the first doctor blade, and the first doctor blade is provided with an emission opening adapted to produce a blade of a predetermined gas directed towards the powder bed, and the second doctor blade is provided with a suction opening for sucking in the gas when the product is complete, the suction opening being provided with a sensor adapted to measure the turbulence of the gas flow in the work area, so as to maintain, through a control uType: GrantFiled: April 13, 2017Date of Patent: August 17, 2021Assignee: 3D New Technologies S.R.L.Inventors: Mauro Varetti, Fabio Ferrario
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Patent number: 11084218Abstract: Apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective consolidation of layers of a build material (3) which can be consolidated by means of an energy source (4), which apparatus (1) comprises a stream generating device (6) adapted to generate a gas stream (7) in a process chamber (8) of the apparatus (1) and an application device (18) comprising an application unit (19) with an application element (20) that is moveable across a build plane (14) of the apparatus (1) for applying build material (3) in the build plane (14), wherein the application device (18) comprises at least one stream guiding unit (22) that is adapted to guide the gas stream (7) along a streaming path (26).Type: GrantFiled: March 6, 2019Date of Patent: August 10, 2021Assignee: CONCEPT LASER GMBHInventor: Bernhard Moritz
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Patent number: 11052610Abstract: A powder delivery device for providing raw material powder to a powder application device of a powder bed fusion apparatus is provided. The powder delivery device comprises a powder supply section configured to receive raw material powder, the powder supply section comprising an outlet for providing the raw material powder to the powder application device. The powder delivery device further comprises a first physical parameter determining unit arranged at a first location of the powder supply section and configured to determine a first physical parameter in the powder supply section, and a controller configured to determine whether the first physical parameter meets a first tolerance criterion, and a powder treatment unit. The controller is configured to instruct the powder treatment unit to perform a powder treatment in case it determines that the first physical parameter does not meet the first tolerance criterion.Type: GrantFiled: February 12, 2019Date of Patent: July 6, 2021Assignee: SLM Solutions Group AGInventors: Henner Schoeneborn, Lukas Roesgen
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Patent number: 11009863Abstract: A computer-implemented method for predicting material properties in an Additive Manufacturing (AM) process is provided.Type: GrantFiled: June 14, 2018Date of Patent: May 18, 2021Assignee: HONEYWELL INTERNATIONAL INC.Inventors: Raj Mohan Bharadwaj, Andrew Peter Vechart, Suresh Sundarraj, Piyush Ranade
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Patent number: 10974321Abstract: 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: GrantFiled: October 11, 2019Date of Patent: April 13, 2021Assignee: Hamilton Sundstrand CorporationInventor: Eric W. Karlen
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Patent number: 10953599Abstract: 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: GrantFiled: May 12, 2016Date of Patent: March 23, 2021Assignee: Hewlett-Packard Development Company, L.P.Inventors: Xavier Vilajosana, Alejandro Manuel De Pena, Sebastia Cortes I Herms
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Patent number: 10940533Abstract: 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: GrantFiled: October 22, 2018Date of Patent: March 9, 2021Assignee: Desktop Metal, Inc.Inventors: George Hudelson, Emanuel M. Sachs, Glenn A. Jordan, Midnight Zero
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Patent number: 10933583Abstract: 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: GrantFiled: January 9, 2020Date of Patent: March 2, 2021Assignee: Seiko Epson CorporationInventors: Takeshi Miyashita, Naoko Shima, Jun Takizawa
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Patent number: 10919287Abstract: 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: GrantFiled: July 20, 2016Date of Patent: February 16, 2021Assignee: SLM SOLUTIONS GROUP AGInventors: Andreas Wiesner, Dieter Schwarze, Toni Adam Krol
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Patent number: 10898954Abstract: 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: GrantFiled: February 19, 2020Date of Patent: January 26, 2021Assignee: Lawrence Livermore National Security, LLCInventors: James A. Demuth, Andrew J. Bayramian, Bassem S. El-Dasher, Joseph C. Farmer, Kevin J. Kramer, Alexander Rubenchik
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Patent number: 10888924Abstract: 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: GrantFiled: January 26, 2018Date of Patent: January 12, 2021Assignee: RAYTHEON TECHNOLOGIES CORPORATIONInventors: Sergei F. Burlatsky, David Ulrich Furrer, Rebecca L. Runkle, Jesse R. Boyer, Christopher F. O'Neill
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Patent number: 10885214Abstract: 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: GrantFiled: December 13, 2017Date of Patent: January 5, 2021Inventors: Claus Gosch, Peter Linde, Matthias Hegenbart
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Patent number: 10872732Abstract: 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: GrantFiled: September 4, 2017Date of Patent: December 22, 2020Assignee: TANIOBIS GMBHInventors: Helmut Haas, Marcel Hagymasi, Kamil Paul Rataj, Christoph Schnitter, Markus Weinmann
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Patent number: 10800103Abstract: 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: GrantFiled: November 13, 2017Date of Patent: October 13, 2020Assignee: Applied Materials, Inc.Inventors: Hou T. Ng, Nag B. Patibandla, Ajey M. Joshi, Raanan Zehavi, Jeffrey L. Franklin, Kashif Maqsood
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Patent number: 10799951Abstract: 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: GrantFiled: February 11, 2016Date of Patent: October 13, 2020Assignee: GENERAL ELECTRIC COMPANYInventor: Daniel Joerger
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Patent number: 10786865Abstract: 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: GrantFiled: November 24, 2015Date of Patent: September 29, 2020Assignee: Arcam ABInventor: Calle Hellestam
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Patent number: 10751940Abstract: 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: GrantFiled: October 27, 2016Date of Patent: August 25, 2020Assignee: 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
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Patent number: 10730240Abstract: 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: GrantFiled: November 13, 2017Date of Patent: August 4, 2020Assignee: Applied Materials, Inc.Inventors: Hou T. Ng, Nag B. Patibandla, Ajey M. Joshi, Raanan Zehavi, Jeffrey L. Franklin, Kashif Maqsood
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Patent number: 10730239Abstract: 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: GrantFiled: November 10, 2019Date of Patent: August 4, 2020Inventors: Yuri Glukhoy, Tatiana Kerzhner, Anna Ryaboy, Joshua Kerzhner, Michael Ryaboy, Andrew Kerzhner, Kevin Kerzhner
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Patent number: 10695832Abstract: 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: GrantFiled: October 6, 2017Date of Patent: June 30, 2020Assignee: GENERAL ELECTRIC TECHNOLOGY GMBHInventors: Matthias Hoebel, Mikhail Pavlov, Thomas Etter, Roman Engeli
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Patent number: 10695865Abstract: 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: GrantFiled: March 3, 2017Date of Patent: June 30, 2020Assignee: General Electric CompanyInventors: Michael Evans Graham, Lang Yuan
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Patent number: 10610930Abstract: 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: GrantFiled: November 7, 2016Date of Patent: April 7, 2020Assignee: Arcam ABInventors: Johan Nordkvist, Ulf Ackelid
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Patent number: 10576543Abstract: 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: GrantFiled: January 22, 2015Date of Patent: March 3, 2020Assignee: United Technologies CorporationInventors: Aaron T. Nardi, Zissis Dardas
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Patent number: 10525530Abstract: 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: GrantFiled: July 26, 2018Date of Patent: January 7, 2020Assignee: Matsuura Machinery Corp.Inventors: Kouichi Amaya, Toshihiko Kato, Tetsushi Midorikawa, Mitsuyoshi Yoshida, Kazuhiro Shimizu
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Patent number: 10507549Abstract: 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: GrantFiled: February 17, 2017Date of Patent: December 17, 2019Assignee: VELO3D, INC.Inventors: Benyamin Buller, Erel Milshtein, Thai Cheng Chua
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Patent number: 10338569Abstract: 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: GrantFiled: August 15, 2017Date of Patent: July 2, 2019Assignee: GENERAL ELECTRIC COMPANYInventors: Donnell Eugene Crear, Michael Evans Graham, Tao Jia, Mohammed Mounir Shalaby
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Patent number: 10335856Abstract: 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: GrantFiled: June 28, 2016Date of Patent: July 2, 2019Assignee: Applied Materials, Inc.Inventors: Bharath Swaminathan, Eric Ng, Nag B. Patibandla, Hou T. Ng, Ashavani Kumar, Ajey M. Joshi, Bernard Frey, Kasiraman Krishnan
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Patent number: 10259042Abstract: 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: GrantFiled: January 22, 2016Date of Patent: April 16, 2019Assignee: MTU Aero Engines AGInventor: Maximilian Fisser
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Patent number: 10183444Abstract: 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: GrantFiled: April 22, 2015Date of Patent: January 22, 2019Assignee: Xerox CorporationInventor: Richard A. Campbell