US 11,731,208 B2
Systems and methods providing dynamic bead spacing and weave fill in additive manufacturing
Andrew R. Peters, Chesterland, OH (US); Jonathan H. Paul, Knoxville, TN (US); and Levi J. Mitchell, Windsor, CO (US)
Assigned to LINCOLN GLOBAL, INC., Santa Fe Springs, CA (US)
Filed by Lincoln Global, Inc., Santa Fe Springs, CA (US)
Filed on Feb. 24, 2022, as Appl. No. 17/679,218.
Application 17/679,218 is a continuation of application No. 16/239,602, filed on Jan. 4, 2019, granted, now 11,305,366.
Prior Publication US 2022/0176483 A1, Jun. 9, 2022
Int. Cl. B23K 9/02 (2006.01); B23K 26/342 (2014.01); B23K 9/025 (2006.01); B23K 9/028 (2006.01); B23K 9/095 (2006.01); B23K 9/12 (2006.01); B33Y 10/00 (2015.01); B23K 37/02 (2006.01); B23K 37/04 (2006.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01)
CPC B23K 9/0216 (2013.01) [B23K 9/025 (2013.01); B23K 9/028 (2013.01); B23K 9/0953 (2013.01); B23K 9/125 (2013.01); B23K 9/126 (2013.01); B23K 26/342 (2015.10); B23K 37/0252 (2013.01); B23K 37/04 (2013.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12)] 19 Claims
OG exemplary drawing
 
1. An additive manufacturing system, the system comprising:
a computer control means configured to access multiple planned build patterns, stored as digital data, corresponding to multiple build layers of a three-dimensional (3D) part to be additively manufactured; and
a metal deposition apparatus configured to deposit metal material to form at least a portion of a build layer of the multiple build layers of the 3D part, wherein the metal deposition apparatus includes:
a deposition tool having a contact tip,
a wire feeder operatively connected to the deposition tool and configured to feed a consumable wire electrode of the metal material toward the 3D part through the deposition tool, and
a power source operatively connected to the wire feeder,
wherein the power source is configured to provide energy to melt at least the consumable wire electrode during deposition of a beaded weave pattern by forming an arc between the consumable wire electrode and the 3D part, and
wherein the metal material is deposited as the beaded weave pattern, in accordance with a planned path of a planned build pattern of the multiple planned build patterns, under control of the computer control means, where the planned build pattern corresponds to the build layer, and
wherein a wire feed speed and at least one of a weave width, a weave frequency, and a weave dwell of the beaded weave pattern are dynamically adjusted during deposition of the beaded weave pattern, under control of the computer control means in accordance with the planned build pattern, as a width of the build layer varies along a length dimension of the build layer, resulting in a dynamically varying bead width of the beaded weave pattern.