US 12,337,529 B2
Compensating laser alignment for irregularities in an additive manufacturing machine powderbed
Brian Scott McCarthy, Schenectady, NY (US); Dean Andrew Snelling, Jr., Statesboro, GA (US); Thomas Adcock, Glenville, NY (US); Donnell Crear, Simpsonville, SC (US); and Michael Evans Graham, Slingerlands, NY (US)
Assigned to General Electric Company, Schenectady, NY (US)
Filed by General Electric Company, Schenectady, NY (US)
Filed on May 15, 2023, as Appl. No. 18/317,437.
Application 18/317,437 is a continuation of application No. 16/289,076, filed on Feb. 28, 2019, granted, now 11,679,551.
Prior Publication US 2023/0278282 A1, Sep. 7, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 64/153 (2017.01); B22F 10/20 (2021.01); B22F 10/31 (2021.01); B22F 12/90 (2021.01); B29C 64/268 (2017.01); B29C 64/393 (2017.01); B33Y 50/02 (2015.01); B22F 12/45 (2021.01); B22F 12/49 (2021.01); B22F 12/60 (2021.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01)
CPC B29C 64/153 (2017.08) [B22F 10/20 (2021.01); B22F 10/31 (2021.01); B22F 12/90 (2021.01); B29C 64/268 (2017.08); B29C 64/393 (2017.08); B33Y 50/02 (2014.12); B22F 12/45 (2021.01); B22F 12/49 (2021.01); B22F 12/60 (2021.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12)] 20 Claims
OG exemplary drawing
 
1. A system for energy beam alignment error compensation in an additive manufacturing machine, the system comprising:
a processor unit configured to execute executable instructions that cause the processor unit to perform a method, the method including:
collecting data from one or more sensors, the data representing height variations across at least a portion of a first surface of a powderbed;
deriving dimensional data from the collected data;
analyzing the dimensional data to determine a distribution of differences between the first surface and a calibration plane used for a first spatial calibration; and
calculating z-axis calibration offset points for inclusion in a calibration table containing x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between commanded locations and the first spatial calibration, the z-axis calibration offset points adjusting the x-y planar offsets.