Additive manufacturing methods and systems with fiber reinforcement

{
  "publication_number": "US9757802B2",
  "country": "US",
  "kind": "B2",
  "title": "Additive manufacturing methods and systems with fiber reinforcement",
  "abstract": "Additive manufacturing methods for fabricating a fiber-reinforced composite objects include providing at least a first layer of powder material, disposing a fiber material adjacent the at least first layer of powder material to form a fiber reinforcement layer, and applying a laser energy to the at least first layer of powder material so as to fuse the powder material into at least a first laser fused material layer adjacent the fiber reinforcement layer of the fiber-reinforced composite object.",
  "claims": [
    "1. An additive manufacturing method for fabricating a fiber reinforced composite object, the additive manufacturing method comprising: providing at least a first layer of powder material; disposing a fiber material adjacent the at least first layer of powder material to form a fiber reinforcement layer; and, applying a laser energy to the at least first layer of powder material so as to fuse the powder material into at least a first laser fused material layer adjacent the fiber reinforcement layer of the fiber-reinforced composite object.",
    "2. The additive manufacturing method of claim 1, further comprising: providing at least a second layer of powder material; and, applying a laser energy to the at least second layer of powder material so as to fuse the powder material into at least a second laser fused material layer of the fiber reinforced composite object.",
    "3. The additive manufacturing method of claim 2, further comprising disposing an additional fiber material adjacent the at least second layer of powder material to form an additional fiber reinforcement layer.",
    "4. The additive manufacturing method of claim 1, wherein the powder material comprises a cobalt-chrome alloy.",
    "5. The additive manufacturing method of claim 1, wherein the fiber material comprises fiber.",
    "6. The additive manufacturing method of claim 1, wherein the fiber material comprises hollow tubes.",
    "7. The additive manufacturing method of claim 1, wherein applying the laser energy to the at least first layer of powder material comprises a plurality of passes of the laser energy.",
    "8. The additive manufacturing method of claim 1, wherein a diameter of the fiber material is less than or equal to a build layer thickness of the powder material."
  ],
  "description_excerpt": "The subject matter disclosed herein relates to additive manufacturing methods and systems and, more specifically, to additive manufacturing methods and systems with fiber reinforcement.\n\nAdditive manufacturing processes generally involve the buildup of one or more materials to make a net or near net shape object, in contrast to subtractive manufacturing methods. Though “additive manufacturing” is an industry standard term (ASTM F2792), additive manufacturing encompasses various manufacturing and prototyping techniques known under a variety of names, including freeform fabrication, 3D printing, rapid prototyping/tooling, etc. Additive manufacturing techniques are capable of fabricating complex components from a wide variety of materials. Generally, a freestanding object can be fabricated from a computer aided design (CAD) model. One exemplary additive manufacturing process uses an energy beam, for example, an electron beam or electromagnetic radiation such as a laser beam, to sinter or melt a powder material, creating a solid three-dimensional object in which particles of the powder material are bonded together. Different material systems, for example, engineering plastics, thermoplastic elastomers, metals, and ceramics may be used. Laser sintering or melting is one exemplary additive manufacturing process for rapid fabrication of functional prototypes and tools. Applications can include patterns for investment casting, metal molds for injection molding and die casting, molds and cores for sand casting, and relatively complex components themselves.",
  "cpc": [
    "C22C 47/14",
    "B22F 10/28",
    "B22F 3/1055",
    "B23K 26/00",
    "B23K 26/342",
    "B28B 1/001",
    "B29C 64/153",
    "B29C 67/0077",
    "B33Y 10/00",
    "B33Y 80/00",
    "C22C 49/02",
    "Y02P 10/25",
    "Y02P 10/295"
  ],
  "ipc": [
    "B23K 26/34",
    "B22F 3/105",
    "B23K 26/00",
    "B23K 26/342",
    "B29C 67/00",
    "C22C 47/14",
    "C22C 49/02"
  ],
  "assignees": [
    "General Electric Co"
  ],
  "inventors": [
    "Yan Cui",
    "Srikanth Chandrudu Kottilingam",
    "Dechao Lin",
    "David Edward Schick"
  ],
  "filing_date": "2014-06-30",
  "publication_date": "2017-09-12",
  "grant_date": "2017-09-12",
  "priority_date": "2014-06-30",
  "application_number": "US-201414318909-A",
  "family_id": "53514004",
  "cited_by_count": 17,
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}