公开(公告)号：US11327870B2

公开(公告)日：2022-05-10

申请号：US16242194

申请日：2019-01-08

Applicant: General Electric Company

Inventor： Harry Kirk Mathews, Jr. ,  Sarah Felix ,  Subhrajit Roychowdhury ,  Saikat Ray Majumder ,  Thomas Spears

IPC: G06F11/34 ,  B29C64/393 ,  G06F17/18 ,  B33Y50/02 ,  G06F30/00

Abstract: Generating fault indications for an additive manufacturing machine based on a comparison of the outputs of multiple process models to measured sensor data. The method receiving sensor data from the additive manufacturing machine during manufacture of at least one part. Models are selected from a model database, each model generating expected sensor values for a defined condition. Difference values are computed between the received sensor data and an output of each of the models. A probability density function is computed, which defines, for each of the models, a likelihood that a given difference value corresponds to each respective model. A probabilistic rule is applied to determine, for each of the models, a probability that the corresponding model output matches the received sensor data. An indicator is output of a defined condition corresponding to a model having the highest match probability.

公开(公告)号：US11065820B2

公开(公告)日：2021-07-20

申请号：US16260662

申请日：2019-01-29

Applicant: General Electric Company

Inventor： Nitish Umang ,  Kai Hertel ,  Christian Wacker ,  Subhrajit Roychowdhury ,  David Toledano ,  Srinivas Bollapragada

IPC: B29C64/393 ,  B29C64/153 ,  B29C64/268 ,  B22F10/20 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B22F10/30

Abstract: According to some embodiments, system and methods are provided comprising receiving input including: coordinates of one or more regions to be fabricated on a build plate, a laser boundary for each of two or more lasers, wherein the lasers fabricate the one or more regions, and a processing time for each region; deriving a prioritized sequence of the one or more regions to be fabricated; determining, based on the received coordinates and received laser boundary, one or more potential lasers assignments for each region; determining, based on the determined potential laser assignments, the prioritized sequence of the one or more regions, and the processing time for each region, a laser-to-region sequence for the one or more lasers to fabricate the one or more regions; assigning the determined laser-to-region sequence to the one or more lasers for fabrication of the one or more regions. Numerous other aspects are provided.

公开(公告)号：US10747202B2

公开(公告)日：2020-08-18

申请号：US15638998

申请日：2017-06-30

Applicant: General Electric Company

Inventor： Rogier Sebastiaan Blom ,  John Freer ,  Dean Michael Robinson ,  Subhrajit Roychowdhury ,  Harry Kirk Mathews, Jr.

IPC: G05B19/00 ,  G05B19/4099 ,  G01J5/04 ,  G01J5/00 ,  B33Y50/00 ,  G01B11/02 ,  G01B11/22 ,  G01B11/28 ,  G01J5/10 ,  G01J5/08

Abstract: A manufacturing computer device for dynamically adapting additive manufacturing of a part is configured to store a build file for building the part including one or more build parameters and receive build information. The manufacturing computer device is also configured to compare the sensor information to the one or more build parameters to determine one or more differences. The computer device is further configured to determine one or more adjustments to the one or more build parameters. Moreover, the computer device is configured to generate an updated build file based on the one or more adjustments. In addition, the computer device is further configured to transmit the updated build file to at least one machine of the plurality of machines for manufacture.

公开(公告)号：US20200031042A1

公开(公告)日：2020-01-30

申请号：US16046693

申请日：2018-07-26

Applicant: General Electric Company

Inventor： Michael Evans Graham ,  William Thomas Carter ,  John Broddus Deaton, JR. ,  John Joseph Madelone, JR. ,  Thomas Charles Adcock ,  Matthias Hoebel ,  Subhrajit Roychowdhury

IPC: B29C64/153 ,  B29C64/20 ,  B29C64/393 ,  B28B1/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  C03B19/01 ,  B23K26/342

Abstract: An additive manufacturing system includes a build platform, a plurality of particles positioned on the build platform defining a build layer, a first and second region within the build layer, and at least one consolidation device. The first region and the second region each including a portion of the plurality of particles. The at least one consolidation device is configured to consolidate the plurality of particles within the build layer into a solid, consolidated portion of said build layer. The consolidation device is further configured to consolidate at least one of the plurality of particles within the build layer and the solid, consolidated portion of the build layer into a molten volume of transfer material. The consolidation device is further configured to transfer a portion of the molten volume of transfer material within the first region from the first region to the second region.

公开(公告)号：US10514680B2

公开(公告)日：2019-12-24

申请号：US15665086

申请日：2017-07-31

Applicant: General Electric Company

Inventor： John Joseph Madelone, Jr. ,  Thomas Charles Adcock ,  Justin John Gambone, Jr. ,  Michael Evans Graham ,  Subhrajit Roychowdhury ,  Daniel J. Erno

IPC: G05B19/4099 ,  B23K26/342 ,  B23K26/082 ,  B33Y50/02 ,  B33Y30/00 ,  B33Y10/00

Abstract: A method of manufacturing a component using an additive manufacturing system is provided. The method includes providing a build file on a controller of the additive manufacturing system. The build file includes at least one generating function, at least one seed value, and at least one function parameter. The method also includes generating a curve that corresponds to the component based on the at least one generating function, the at least one seed value, and the at least one function parameter. The method further includes positioning a material on a surface. The method further includes determining, using the controller, a plurality of set points for a consolidation device. The plurality of set points are located along the curve. The method also includes operating the consolidation device of the additive manufacturing system to consolidate the material.

公开(公告)号：US20190033828A1

公开(公告)日：2019-01-31

申请号：US15665086

申请日：2017-07-31

Applicant: General Electric Company

Inventor： John Joseph Madelone, JR. ,  Thomas Charles Adcock ,  Justin John Gambone, JR. ,  Michael Evans Graham ,  Subhrajit Roychowdhury ,  Daniel J. Erno

IPC: G05B19/4099 ,  B23K26/342 ,  B23K26/082 ,  B33Y50/02 ,  B33Y30/00 ,  B33Y10/00

Abstract: A method of manufacturing a component using an additive manufacturing system is provided. The method includes providing a build file on a controller of the additive manufacturing system. The build file includes at least one generating function, at least one seed value, and at least one function parameter. The method also includes generating a curve that corresponds to the component based on the at least one generating function, the at least one seed value, and the at least one function parameter. The method further includes positioning a material on a surface. The method further includes determining, using the controller, a plurality of set points for a consolidation device. The plurality of set points are located along the curve. The method also includes operating the consolidation device of the additive manufacturing system to consolidate the material.

公开(公告)号：US20190004079A1

公开(公告)日：2019-01-03

申请号：US15638943

申请日：2017-06-30

Applicant: General Electric Company

Inventor： Rogier Sebastiaan Blom ,  John Freer ,  Dean Michael Robinson ,  Subhrajit Roychowdhury ,  Harry Kirk Mathews, JR.

IPC: G01N35/10 ,  B22F3/105 ,  B33Y50/02 ,  G06F19/00

CPC classification number: G01N35/1011 ,  B22F3/1055 ,  B22F2003/1057 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  G06F19/00

Abstract: A manufacturing computer device for dynamically adapting additive manufacturing of a part is provided. The manufacturing computer device includes at least one processor in communication with at least one memory device. The at least one memory device stores a build file for building the part including a plurality of geometries that each include one or more values of a first build parameter. The processor is programmed to receive sensor information of a build of the part by a machine, compare the sensor information for each geometry of the plurality of geometries to the corresponding one or more values of the first build parameter, determine one or more values for a second build parameter for each of the geometries based on the one or more differences, and generate an updated build file for the part including the one or more values for the second build parameter.

公开(公告)号：US20190001655A1

公开(公告)日：2019-01-03

申请号：US15638913

申请日：2017-06-30

Applicant: General Electric Company

Inventor： Rogier Sebastiaan Blom ,  John Freer ,  Dean Michael Robinson ,  Subhrajit Roychowdhury ,  Harry Kirk Mathews, JR.

IPC: B33Y30/00 ,  B22F3/105 ,  B33Y70/00 ,  C25D21/12 ,  B33Y50/02

Abstract: A manufacturing computer device for dynamically adapting additive manufacturing of a part is configured to store a model of the part including a plurality of build parameters. The manufacturing computer device is also configured to receive current sensor information of at least one current sensor reading of a melt pool from a build of the part in progress. The computer device is further configured to determine one or more attributes of the melt pool based on the current sensor information. Moreover, the computer device is configured to calculate at least one unseen attribute of the melt pool. In addition, the computer device is configured to determine an adjusted build parameter based on the at least one unseen attribute, the one or more attributes, and the plurality of build parameters. The computer device is also configured to transmit the adjusted build parameter to a machine currently manufacturing the part.

公开(公告)号：US20240342831A1

公开(公告)日：2024-10-17

申请号：US18752404

申请日：2024-06-24

Applicant: General Electric Company

Inventor： Naresh S. Iyer ,  Subhrajit Roychowdhury ,  Christopher D. Immer ,  Xiaohu Ping ,  Rogier S. Blom ,  Jing Yu

IPC: B23K26/342 ,  B23K26/03 ,  B23K26/06 ,  B23K26/073 ,  B23K26/082 ,  B23K31/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

CPC classification number: B23K26/342 ,  B23K26/032 ,  B23K26/0626 ,  B23K26/073 ,  B23K26/082 ,  B23K31/003 ,  B23K31/006 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: An example additive manufacturing apparatus includes an energy source to melt material to form a component in an additive manufacturing process, a camera aligned with the energy source to obtain image data of the melted material during the additive manufacturing process, and a controller to control the energy source during the additive manufacturing process in response to processing of the image data. The controller adjusts control of the energy source based on a correction determined by: applying an artificial intelligence model to image data captured by a camera during an additive manufacturing process, the image data including an image of a melt pool of the additive manufacturing process; predicting an error in the additive manufacturing process using an output of the artificial intelligence model; and compensating for the error by generating a correction to adjust a configuration of the energy source during the additive manufacturing process.

公开(公告)号：US12023860B2

公开(公告)日：2024-07-02

申请号：US17967391

申请日：2022-10-17

Applicant: General Electric Company

Inventor： Vipul Kumar Gupta ,  Natarajan Chennimalai Kumar ,  Anthony Joseph Vinciquerra ,  Laura Cerully Dial ,  Voramon Supatarawanich Dheeradhada ,  Timothy Hanlon ,  Lembit Salasoo ,  Xiaohu Ping ,  Subhrajit Roychowdhury ,  Justin John Gambone

IPC: B29C64/153 ,  B22F10/20 ,  B22F10/31 ,  B22F10/85 ,  B29C64/393 ,  B33Y50/00 ,  B22F3/24 ,  B22F10/28 ,  B22F10/30 ,  B22F10/366 ,  B22F12/90 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

CPC classification number: B29C64/153 ,  B22F10/20 ,  B22F10/31 ,  B22F10/85 ,  B29C64/393 ,  B33Y50/00 ,  B22F2003/245 ,  B22F10/28 ,  B22F10/30 ,  B22F10/366 ,  B22F12/90 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.