# US 10,478,892 B2 · Additive manufacturing process distortion management

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- Number: US 10,478,892 B2
- Document ID: US10478892B2
- Status: Granted
- Kind: B2
- Application number: 15/109,514
- Filed: 2015-01-02
- Published: 2016-11-10
- Granted: 2019-11-19
- Earliest claimed: 2014-01-02
- Assignees: United Technologies Corporation
- Applicants: United Technologies Corporation
- Inventors: Sergey Mironets; Lexia Kironn; Joe Ott; Louis Porretti
- Web page: https://patentgrep.com/patent/US10478892B2

## CPC

- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B22F 12/67: Blades
- B29C 64/214: Doctor blades
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/80: Data acquisition or data processing
- B22F 12/41: characterised by the type, e.g. laser or electron beam
- Y02P 10/25: Process efficiency
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method is provided for additive manufacturing. This method includes monitoring a current to a recoater blade. The monitored current is compared to a predetermined current. An operation is initiated in response to the monitored current exceeding the predetermined current. Another method for additive manufacturing includes comparing a movement of a recoater blade to an expected movement. A single exposure sequence is initiated in response to movement of the recoater blade being different than an expected movement. An additive manufacturing system is also provided which includes a recoated blade and a control. The control is operable to identify resistance to movement of the recoater blade.

## Claims

### Claim 1

A method of additive manufacturing, comprising:
monitoring a current to a recoater blade and providing a monitored current load indicative thereof;
comparing the monitored current load to a predetermined current value; and
initiating a single exposure sequence in response to the monitored current load exceeding the predetermined current.

### Claim 2 (depends on 1)

The method as recited in claim 1, wherein the single exposure sequence operates a laser.

### Claim 3 (depends on 1)

The method as recited in claim 1, wherein the single exposure sequence restrains movement of the recoater blade.

### Claim 4 (depends on 1)

The method as recited in claim 1, further comprising initiating an ultrasonic impact treatment in response to the monitored current load exceeding the predetermined current value.

### Claim 5 (depends on 1)

The method as recited in claim 1, further comprising identifying where the monitored current load exceeds the predetermined current.

### Claim 6 (depends on 1)

The method as recited in claim 1, wherein the single exposure sequence operates an electron beam.

### Claim 7

A method of additive manufacturing, comprising:
monitoring a current to a recoater blade and providing a monitored current load indicative thereof;
comparing the monitored current value to a predetermined current value; and
initiating an ultrasonic impact treatment in response to the monitored current load exceeding the predetermined current.

### Claim 8 (depends on 7)

The method of claim 7, further comprising identifying where the monitored current load exceeds the predetermined current.

### Claim 9 (depends on 8)

The method of claim 8, further comprising initiating a single exposure sequence in response to the monitored current load exceeding the predetermined current.