US4938816A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Selective laser sintering with assisted powder handling
Assignee: The University of Texas System
•
Filing: 1989-09-05
•
Granted: 1990-07-03
•
Expires: 2009-09-05
Abstract
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 is deposited to the target area of the laser and attains high bulk density during sintering.
Inventors
- 👤 Joseph J. Beaman
- 👤 Carl R. Deckard
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 19:28
CPC Classifications
C; C23; C23C; C23C26/00; C23C26/02; B; B05; B05C; B05C19/00; B05C19/008; B22; B22F; B22F10/00; B22F10/20; B22F10/28; B22F10/30; B22F10/36; B22F10/366; B22F12/00; B22F12/40; B22F12/44; B22F3/00; B22F3/004; B22F3/10; B22F3/105; B22F7/00; B22F7/02; B23; B23K; B23K26/00; B23K26/08; B23K26/082; B23K26/34; B29; B29C; B29C41/00; B29C41/02; B29C41/12; B29C41/34; B29C41/46; B29C64/00; B29C64/10; B29C64/141; B29C64/153; B33; B33Y; B33Y10/00; B33Y30/00; C23C24/00; C23C24/08; C23C24/10; B22F10/60; B22F12/41; B22F12/43; B22F12/49; B22F12/50; B22F12/52; B22F12/57; B22F2003/1052; B22F2998/00; B22F2998/10; B29C35/00; B29C35/02; B29C35/04; B29C35/045; G; G05; G05B; G05B2219/00; G05B2219/30; G05B2219/49; G05B2219/49013; G05B2219/49018; Y; Y02; Y02P; Y02P10/00; Y02P10/25; Y02P90/00; Y02P90/02
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
109 words
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; means for depositing a powder into said target area; 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 deposited 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; and means for attaining a high bulk density in said powder in said target area.
Claim 2
Independent Claim
109 words
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; means for depositing a powder into said target area; 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 deposited 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; and means for attaining a high bulk density in said powder in said target area.
Claim 3
Dependent Claim
22 words
The apparatus of claim 1 wherein said means for attaining a high bulk density enables attaining a high bulk density during sintering.
Claim 4
Dependent Claim
18 words
The apparatus of claim 1 wherein said depositing means comprises apparatus to electrostatically charge and dispense said powder.
Claim 5
Dependent Claim
37 words
The apparatus of claim 3 wherein said means for attaining comprises means for producing an electromagnetic field proximate said target area, said electromagnetic field inducing high bulk density in said powder in said target area during sintering.
Claim 6
Dependent Claim
26 words
The apparatus of claim 4 wherein said means for producing an electromagnetic field enables production of a field having varying field strengths across said target area.
Claim 7
Dependent Claim
21 words
The apparatus of claim 1 wherein said powder comprises polarizable elements and said depositing means comprise apparatus to dispense said powder.
Claim 8
Dependent Claim
37 words
The apparatus of claim 6 wherein said means for attaining comprises means for producing an electromagnetic field proximate said target area, said electromagnetic field inducing high bulk density in said powder in said target area during sintering.
Claim 9
Dependent Claim
26 words
The apparatus of claim 7 wherein said means for producing an electromagnetic field enables production of a field having varying field strengths across said target area.
Claim 10
Dependent Claim
43 words
The apparatus of claim 1 wherein said depositing means comprises an apparatus to dispense said powder with a first electrical charge and said target area having a second electrical charge, said first electrical charge being of opposite charge to said second electrical charge.
Claim 11
Dependent Claim
38 words
The apparatus of claim 1 wherein said depositing means comprises: apparatus to dispense a first portion of said powder with a first electrical charge on said first portion; and a contouring means passable proximal said dispensed first portion.
Claim 12
Dependent Claim
42 words
The apparatus of claim 10 wherein said depositing means further comprises apparatus to dispense a second portion of said powder with a second electrical charge on said second portion, said first electrical charge being of opposite charge to said second electrical charge.
Claim 13
Dependent Claim
138 words
The apparatus of claim 1 wherein said depositing means further comprises a device for distributing a mound of powder at one end of a region as a layer of powder in the region, comprising: electrically charged drum means; means for moving the drum from said one end of the region to another end of the region with a desired spacing between said region and drum; means for rotating the drum counter to the direction of movement of the drum from said one end to said other end, said drum means being operable when counter-rotated and moved from said one end to said other end to contact said mound and eject powder in said direction of movement to leave a layer of powder between the drum means and said one end having a thickness of approximately said desired spacing.
Claim 14
Dependent Claim
42 words
The apparatus of claim 1 wherein said powder is magnetic and said means for attaining comprises means for producing an electromagnetic field proximate said target area, said electromagnetic field inducing high bulk density in said powder in said target area during sintering.
Claim 15
Dependent Claim
38 words
The apparatus of claim 1 wherein said powder is polarizable and said means for attaining comprises means for producing an electromagnetic field, said electromagnetic field inducing high bulk density in said powder in said target area during sintering.
Claim 16
Dependent Claim
38 words
The apparatus of claim 1 wherein said means for attaining comprises apparatus for directing a fluid stream to said powder deposited in said target area inducing high bulk density in said powder in said target area during sintering.
Claim 17
Dependent Claim
35 words
The apparatus of claim 1 wherein said means for attaining comprises apparatus to enable the application of centrifugal force to said deposited powder to induce high bulk density in said powder in said target area.
Claim 18
Independent Claim
191 words
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, the first and second layers being joined during the sintering of said second layer; depositing successive portions of powder in high bulk density onto the previous sintered layers and sintering a layer of each successive portion to produce a part comprising a plurality of sintered layers; and attaining high bulk density in each said portion of powder in said target area.
Claim 19
Independent Claim
191 words
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, the first and second layers being joined during the sintering of said second layer; depositing successive portions of powder in high bulk density onto the previous sintered layers and sintering a layer of each successive portion to produce a part comprising a plurality of sintered layers; and attaining high bulk density in each said portion of powder in said target area.
Claim 20
Dependent Claim
20 words
The method of claim 17 wherein said step of attaining attains a high bulk density while sintering said deposited powder.
Claim 21
Dependent Claim
25 words
The method of claim 17 wherein at least one of said steps of depositing further comprises the substeps of electrostatically charging and dispensing said powder.
Claim 22
Dependent Claim
52 words
The method of claim 17 wherein at least one of said steps of depositing further comprises the substep of electrostatically charging and dispensing said powder and said step of attaining comprises producing an electromagnetic field proximate said target surface, said electromagnetic field inducing high bulk density in said deposited powder during sintering.
Claim 23
Dependent Claim
16 words
The method of claim 17 wherein at least one of said portions of powder is polarizable.
Claim 24
Dependent Claim
42 words
The method of claim 17 wherein at least one of said portions of powder is polarizable and said attaining step comprises producing an electromagnetic field proximate said target surface, said electromagnetic field inducing high bulk density in said deposited powder during sintering.
Claim 25
Dependent Claim
50 words
The method of claim 17 wherein at least one of said steps of depositing further comprises the substeps of: dispensing said powder with a first electrical charge; and placing a second electrical charge on said target surface, said first electrical charge being of opposite charge to said second electrical charge.
Claim 26
Dependent Claim
46 words
The method of claim 17 wherein at least one of said steps of depositing further comprises the substeps of: placing a first electrical charge on a first subportion of said powder and dispensing said first subportion; and passing a contouring means proximal said dispensed first subportion.
Claim 27
Dependent Claim
76 words
The method of claim 17 wherein at least one of said steps of depositing further comprises the substeps of: placing a first electrical charge on a first subportion of said powder and dispensing said first subportion; passing a contouring means proximal said dispensed first subportion; and placing a second electrical charge on a second subportion of said powder and dispensing said second subportion, said first electrical charge being of opposite charge to said second electrical charge.
Claim 28
Dependent Claim
37 words
The method of claim 17 wherein said powder is magnetic and said step of attaining comprises producing an electromagnetic field proximate said target surface, said electromagnetic field inducing high bulk density in said deposited powder during sintering.
Claim 29
Dependent Claim
33 words
The method of claim 17 wherein said powder is polarizable and said step of attaining comprises producing an electromagnetic field, said electromagnetic field inducing high bulk density in said deposited powder during sintering.
Claim 30
Dependent Claim
32 words
The method of claim 19 wherein said step of attaining comprises the substep of directing a fluid stream to said deposited powder inducing high bulk density in said deposited powder during sintering.
Claim 31
Dependent Claim
29 words
The method of claim 17 wherein said step of attaining comprises the substep of applying centrifugal force to said deposited powder inducing high bulk density in said deposited powder.
Claim 32
Independent Claim
114 words
A method of applying a layer of powder in a region comprising the steps of: depositing a mound of powder proximate one end of said region; moving an electrically charged drum in a direction from said one end of said region towards another end of the region; rotating the drum counter to the direction of movement from said one end towards the other end; contacting the mound of powder with the counter-rotating drum as it moves towards said other end; ejecting powder from said mound in the direction of movement from contact between said drum and mound, a layer of powder being left behind said moving drum between the drum and said one end.
Claim 33
Independent Claim
114 words
A method of applying a layer of powder in a region comprising the steps of: depositing a mound of powder proximate one end of said region; moving an electrically charged drum in a direction from said one end of said region towards another end of the region; rotating the drum counter to the direction of movement from said one end towards the other end; contacting the mound of powder with the counter-rotating drum as it moves towards said other end; ejecting powder from said mound in the direction of movement from contact between said drum and mound, a layer of powder being left behind said moving drum between the drum and said one end.
References Cited (Backward Citations)
DE137951C
Cited
US2076952A
Cited
GB1215184A
Cited
DE2263777A1
Cited
FR2166526A5
Cited
US3848104A
Cited
US3985995A
Cited
US4117302A
Cited
US4135902A
Cited
US4300474A
Cited
US4270675A
Cited
US4323756A
Cited
JPS57156959A
Cited
JPS57185536A
Cited
US4474861A
Cited
US4540867A
Cited
US4575330A
Cited
US4575330B1
Cited
EP0209366A1
Cited
US4752352A
Cited
US4863538A
Cited
US4818562A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-07-02 | 1994-01-01 | 1994-07-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-07-02 | 1998-01-01 | 1998-07-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-07-02 | 2002-01-01 | 2002-07-03 | $7700.00 | Window Closed / Lapsed |