Multiple material systems for selective beam sintering
First Claim
1. An apparatus for producing a part comprising:
- beam means for selectively emitting a directed energy beam;
structure for providing a target area for producing the part;
powder comprising a plurality of materials, said plurality of materials having more than one dissociation temperature;
means for dispensing said powder; and
control means for moving the aim of the beam and for modulating the beam means to selectively sinter within defined boundaries a layer of powder dispensed in said target area,the control means being operable to effect selective sintering of sequential layers of powder within respective defined boundaries to produce a part comprising a plurality of layers sintered together.
8 Assignments
0 Petitions
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. Preferably, the powder comprises a plurality of materials having different dissociation or bonding temperatures. The powder preferably comprises blended or coated materials.
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Citations
20 Claims
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1. An apparatus for producing a part comprising:
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beam means for selectively emitting a directed energy beam; structure for providing a target area for producing the part; powder comprising a plurality of materials, said plurality of materials having more than one dissociation temperature; means for dispensing said powder; and control means for moving the aim of the beam and for modulating the beam means to selectively sinter within defined boundaries a layer of powder dispensed in said target area, the control means being operable to effect selective sintering of sequential layers of powder within respective defined boundaries to produce a part comprising a plurality of layers sintered together. - View Dependent Claims (3, 5)
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2. An apparatus for producing a part comprising:
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beam means for selectively emitting a directed energy beam; structure for providing a target area for producing the part; powder comprising a plurality of materials, said plurality of materials having more than one bonding temperature; means for dispensing said powder; and control means for moving the aim of the beam and for modulating the beam means to selectively sinter within defined boundaries a layer of powder dispensed in said target area, the control means being operable to effect selective sintering of sequential layers of powder within respective defined boundaries to produce a part comprising a plurality of layers sintered together. - View Dependent Claims (4, 6)
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7. A method of producing a part comprising the steps of:
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depositing a first portion of powder onto a target surface, said first portion of powder comprising a plurality of materials, said plurality of materials having more than one bonding temperature; 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, said second portion of powder comprising a plurality of materials, said plurality of materials having more than one bonding temperature; 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 (9, 10)
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8. A method of producing a part comprising the steps of:
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depositing a first portion of powder onto a target surface, said first portion of powder comprising a plurality of materials, said plurality of materials having more than one dissociation temperature; 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, said second portion of powder comprising a plurality of materials, said plurality of materials having more than one dissociation temperature; 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 (11, 12)
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13. An apparatus for producing a part comprising:
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beam means for selectively emitting a directed energy beam; structure for providing a target area and a gaseous environment promoting sintering for producing the part; powder comprising a plurality of materials, said plurality of materials having more than one dissociation temperature; means for dispensing said powder; and control means for moving the aim of the beam and for modulating the beam means to selectively sinter within defined boundaries a layer of powder dispensed in said target area, the control means being operable to effect selective sintering of sequential layers of powder within respective defined boundaries to produce a part comprising a plurality of layers sintered together.
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14. An apparatus for producing a part comprising:
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beam means for selectively emitting a directed energy beam; structure for providing a target area and a gaseous environment promoting sintering for producing the part; powder comprising a plurality of materials, said plurality of materials having more than one bonding temperature; means for dispensing said powder; and control means for moving the aim of the beam and for modulating the beam means to selectively sinter within defined boundaries a layer of powder dispensed in said target area, the control means being operable to effect selective sintering of sequential layers of powder within respective defined boundaries to produce a part comprising a plurality of layers sintered together.
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15. A method of producing a part comprising the steps of:
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depositing a first portion of powder onto a target surface in a gaseous environment promoting sintering, said first portion of powder comprising a plurality of materials, said plurality of materials having more than one bonding temperature; 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 in a gaseous environment promoting sintering, said second portion of powder comprising a plurality of materials, said plurality of materials having more than one bonding temperature; 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 in a gaseous environment promoting sintering 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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16. A method of producing a part comprising the steps of:
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depositing a first portion of powder onto a target surface in a gaseous environment promoting sintering, said first portion of powder comprising a plurality of materials, said plurality of materials having more than one dissociation temperature; 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 in a gaseous environment promoting sintering, said second portion of powder comprising a plurality of materials, said plurality of materials having more than one dissociation temperature; 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 in a gaseous environment promoting sintering 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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17. An apparatus for producing a part comprising:
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beam means for selectively emitting a directed energy beam; structure for providing a target area for producing the part; a plurality of powders, said plurality of powders having more than one dissociation temperature; means for dispensing each powder of said plurality of powders; and control means for moving the aim of the beam and for modulating the beam means to selectively sinter within defined boundaries a layer of said powders dispensed in said target area, the control means being operable to effect selective sintering of sequential layers of powder within respective defined boundaries to produce a part comprising a plurality of layers sintered together.
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18. An apparatus for producing a part comprising:
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beam means for selectively emitting a directed energy beam; structure for providing a target area for producing the part; a plurality of powders, said plurality of powders having more than one bonding temperature; means for dispensing each powder of said plurality of powders; and control means for moving the aim of the beam and for modulating the beam means to selectively sinter within defined boundaries a layer of said powders dispensed in said target area, the control means being operable to effect selective sintering of sequential layers of powder within respective defined boundaries to produce a part comprising a plurality of layers sintered together.
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19. A method of producing a part comprising the steps of:
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individually depositing each powder of a first plurality of powders onto a target surface, said first powders comprising a plurality of materials, said plurality of materials having more than one bonding temperature; scanning the aim of a directed energy beam over the target surface; sintering a layer of the first powders 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; individually depositing each powder of a second plurality of powders onto the first sintered layer, said second powders comprising a plurality of materials, said plurality of materials having more than one bonding temperature; scanning the aim of a directed energy beam over the first sintered layer; sintering a layer of the second powders 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 layers of powders 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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20. A method of producing a part comprising the steps of:
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individually depositing each powder of a first plurality of powders onto a target surface, said first powders comprising a plurality of materials, said plurality of materials having more than one dissociation temperature; scanning the aim of a directed energy beam over the target surface; sintering a layer of the first powders 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; individually depositing each powder of a second plurality of powders onto the first sintered layer, said second powders comprising a plurality of materials, said plurality of materials having more than one dissociation temperature; scanning the aim of a directed energy beam over the first sintered layer; sintering a layer of the second powders 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 layers of powders 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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Specification