US 12,068,104 B2
Systems and methods for additive manufacturing magnetic solenoids
Jonathan Douglas Hatch, Cleveland, MO (US); Bob Dearth, Kansas City, MO (US); Ida Sanchez, Leawood, KS (US); and Francisco Garcia-Moreno, Spring, TX (US)
Assigned to Honeywell Federal Manufacturing & Technologies, LLC, Kansas City, MO (US)
Filed by Honeywell Federal Manufacturing & Technologies, LLC, Kansas City, MO (US)
Filed on May 11, 2023, as Appl. No. 18/196,020.
Application 18/196,020 is a division of application No. 17/075,265, filed on Oct. 20, 2020, granted, now 11,688,550.
Prior Publication US 2023/0298812 A1, Sep. 21, 2023
Int. Cl. B22F 10/00 (2021.01); B22F 10/25 (2021.01); B23K 26/342 (2014.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 40/20 (2020.01); H01F 41/02 (2006.01); B22F 10/10 (2021.01); B22F 10/64 (2021.01); B22F 10/80 (2021.01); B22F 12/00 (2021.01); B22F 12/10 (2021.01); B22F 12/58 (2021.01); B23K 101/36 (2006.01); B23K 103/04 (2006.01)
CPC H01F 41/02 (2013.01) [B22F 10/00 (2021.01); B22F 10/25 (2021.01); B23K 26/342 (2015.10); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 40/20 (2020.01); B22F 10/10 (2021.01); B22F 10/64 (2021.01); B22F 10/80 (2021.01); B22F 12/10 (2021.01); B22F 12/22 (2021.01); B22F 12/58 (2021.01); B23K 2101/36 (2018.08); B23K 2103/04 (2018.08)] 16 Claims
OG exemplary drawing
 
1. An additive manufacturing system for forming a magnetically-enabled part, the additive manufacturing system comprising:
a build plate;
a material deposition device configured to:
deposit a first plurality of layers of a first additive manufacturing material on the build plate so as to form a base region;
deposit a second plurality of layers of the first additive manufacturing material and a second additive manufacturing material on the first plurality of layers so as to form a transition region; and
deposit a third plurality of layers of the second additive manufacturing material on the second plurality of layers so as to form a terminal region;
a processor configured to:
calculate a mass consumed as the first plurality of layers is being deposited; and
trigger deposition of the second plurality of layers according to a predetermined amount of mass consumed;
a directed energy source configured to melt or sinter the first plurality of layers, the second plurality of layers, and the third plurality of layers,
the additive manufacturing material of at least some of the layers being magnetically permeable such that the transition region includes at least some of the magnetically permeable additive manufacturing material.