Multiple material systems for selective beam sintering

• US 4,944,817 A
• Filed: 09/05/1989
• Issued: 07/31/1990
• Est. Priority Date: 10/17/1986
• Status: Expired due to Term

• Current Assignee: Board of Regents of the University of Texas System (University of Texas System)
• Original Assignee: Board of Regents of the University of Texas System (University of Texas System)
• Inventors: Marcus, Harris L., Beaman, Joseph J., Bourell, David L., Barlow, Joel W., Deckard, Carl R.
• Primary Examiner(s): Powell, William A.
• Application Number:
  US07/402,694
• Time in Patent Office: 329 Days
• Field of Search: 156/62.2, 156/89, 156/272.8, 156/278, 156/242, 156/245, 156/643, 156/345, 156/500, 156/501, 219/121.6, 219/121.61, 219/121.63, 219/121.64, 219/121.65, 219/121.66, 219/121.73, 219/121.8, 219/121.85, 264/58, 264/113, 264/125, 264/126, 264/127, 264/22, 425/174, 419/5, 419/8
• US Class Current: 264/497
• CPC Class Codes: B05C 19/00 Apparatus specially adapted for applying particulate materials to surfaces
• CPC Class Codes: B05C 19/008 Accessories or implements for use in connection with applying particulate materials to surfaces; not provided elsewhere in B05C19/00
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/44 characterised by the configuration of the radiation means
• CPC Class Codes: B22F 12/49 Scanners
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 2003/1052 assisted by energy absorption enhanced by the coating or powder
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/004 Filling molds with powder feeding material to presses in general B30B15/302
• CPC Class Codes: B22F 3/105 by using electric current other than for infrared radiant energy, laser radiation or plasma B22F3/11 takes precedence; by ultrasonic bonding B22F3/115 takes precedence
• CPC Class Codes: B22F 3/26 Impregnating making ferrous alloys by impregnation C22C33/0242
• CPC Class Codes: B22F 7/02 of composite layers B22F7/002 takes precedence
• CPC Class Codes: B23K 26/08 Devices involving relative movement between laser beam and workpiece
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B23K 26/34 Laser welding for purposes other than joining
• CPC Class Codes: B29C 35/045 : using gas or flames
• CPC Class Codes: B29C 41/12 : Spreading-out the material on a substrate , e.g. on the surface of a liquid
• CPC Class Codes: B29C 41/46 : Heating or cooling
• CPC Class Codes: B29C 64/153 : using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: C23C 24/08 : by application of heat or pressure and heat C23C24/04 takes precedence
• CPC Class Codes: C23C 24/10 : with intermediate formation of a liquid phase in the layer
• CPC Class Codes: C23C 26/02 : applying molten material to the substrate
• CPC Class Codes: G05B 19/41 : characterised by interpolation, e.g. the computation of intermediate points between programmed end points to define the path to be followed and the rate of travel along that path G05B19/25, G05B19/31, G05B19/37, G05B19/39, G05B19/40 take precedence
• CPC Class Codes: G05B 2219/49013 : Deposit layers, cured by scanning laser, stereo lithography SLA, prototyping
• CPC Class Codes: G05B 2219/49018 : Laser sintering of powder in layers, selective laser sintering SLS
• CPC Class Codes: Y02P 10/25 : Process efficiency

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.

Claims

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.

3. The apparatus of claim 1 wherein said plurality of materials comprises at least one first material blended with at least one second material.

5. The apparatus of claim 1 wherein said plurality of materials comprises at least one first material coated with at least one second material.

2. 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 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.

4. The apparatus of claim 2 wherein said plurality of materials comprises at least one first material blended with at least one second material.

6. The apparatus of claim 2 wherein said plurality of materials comprises at least one first material coated with at least one second material.

7. A method of producing a part comprising the steps of:

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.

9. The method of claim 7 wherein said plurality of materials comprises at least one first material blended with at least one second material.

10. The method of claim 7 wherein said plurality of materials comprises at least one first material coated with at least one second material.

8. A method of producing a part comprising the steps of:

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.

11. The method of claim 8 wherein said plurality of materials comprises at least one first material blended with at least one second material.

12. The method of claim 8 wherein said plurality of materials comprises at least one first material coated with at least one second material.

13. An apparatus for producing a part comprising:

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.

14. An apparatus for producing a part comprising:

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.

15. A method of producing a part comprising the steps of:

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.

16. A method of producing a part comprising the steps of:

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.

17. 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;

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.

18. 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;

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.

19. A method of producing a part comprising the steps of:

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.

20. A method of producing a part comprising the steps of:

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.