Method and apparatus for producing parts by selective sintering
First Claim
1. A method of producing a part comprising the steps of:
- depositing a first portion of powder onto a target surface;
scanning the aim of a directed energy beam over the target surface;
sintering a first layer of the first powder portion corresponding to a first cross-sectional region of the part by operating the beam when the aim of the beam is within boundaries defined by said first cross-sectional region;
depositing a second portion of powder onto the first sintered layer;
scanning the aim of a directed energy beam over the first sintered layer;
sintering a second layer of the second powder portion corresponding to a second cross-sectional region of the part by operating the beam when the aim of the beam is within boundaries defined by said second cross-sectional region, including the substep of--joiningthe first and second layers during the sintering of the second layer; and
depositing successive portions of powder onto the previous sintered layers and sintering each successive portion to produce successive sintered layers joined to a previous sintered layer and a part comprising a plurality of sintered layers.
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Accused Products
Abstract
A method and apparatus for selectively sintering a layer of powder to produce a part comprising a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. The powder can comprise either plastic, metal, ceramic, or polymer substance. In the preferred embodiment, the aim of the laser is directed in a continuous raster scan and the laser turned on when the beam is aimed with the boundaries of the particular cross-section being formed.
961 Citations
31 Claims
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1. A method of producing a part comprising the steps of:
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depositing a first portion of powder onto a target surface; scanning the aim of a directed energy beam over the target surface; sintering a first layer of the first powder portion corresponding to a first cross-sectional region of the part by operating the beam when the aim of the beam is within boundaries defined by said first cross-sectional region; depositing a second portion of powder onto the first sintered layer; scanning the aim of a directed energy beam over the first sintered layer; sintering a second layer of the second powder portion corresponding to a second cross-sectional region of the part by operating the beam when the aim of the beam is within boundaries defined by said second cross-sectional region, including the substep of--joining the first and second layers during the sintering of the second layer; and depositing successive portions of powder onto the previous sintered layers and sintering each successive portion to produce successive sintered layers joined to a previous sintered layer and a part comprising a plurality of sintered layers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 16)
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11. A method of forming an integral three-dimensional object, comprising the steps of:
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positioning a target in proximity to means for storing and supplying a powder material; depositing a quantity of said powder material into the area of the target; utilizing means for directing an energy beam into the target area to change a property of at least part of said quantity of powder material to form a layer; and repeating said depositing and utilizing steps to form a plurality of said layers; each of said layers being integrally bonded to the next adjacent of said layers by said utilizing steps to form an integral three-dimensional object.
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12. An apparatus for producing a part comprising:
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means for producing a directed energy beam; a powder dispenser having an outlet directed to a target area; means for directing the beam to the target area and for scanning the target area with the aim of the beam in a repetitive pattern; means for controlling the operation of the beam means to selectively sinter powder dispensed in the target area during the scanning pattern, including computer means operatively coupled to the directing means to monitor the aim of the laser beam during the scanning pattern, the computer means being programmed with information indicative of the desired boundaries of a plurality of cross-sectional regions of the part being produced, The computer means being operable for modulating the beam means when the aim of the beam is within the desired boundaries of the first cross-sectional region to sinter a first layer of powder in the target area, and for modulating the beam means when the aim of the beam is within the desired boundaries of the second cross-sectional region to sinter a second layer of powder and to join the first and second layers of powder, and for modulating the beam means when the aim of the beam is within succeeding desired boundaries of succeeding cross-sectional regions to sinter succeeding layers of powder and to join the sintered layers to form said part. - View Dependent Claims (13, 14, 15, 17, 18, 19)
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20. An apparatus for producing a part comprising:
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laser means for selectively emitting a laser beam; structure for providing a target area for producing the part; means for dispensing powder into said target area; and laser control means responsive to a plurality of defined boundaries in which at least some of the boundaries are different for -- moving the aim of the laser beam across the target area, modulating the laser to selectively sinter a first layer of powder dispensed within a first defined boundary in the target area, modulating the laser to selectively sinter subsequent layers of powder dispensed within respective defined boundaries to produce a part comprising a plurality of sintered layers joined together. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31)
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Specification