US5017753A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method and apparatus for producing parts by selective sintering
Assignee: The University of Texas System
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Filing: 1990-06-22
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Granted: 1991-05-21
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Expires: 2010-06-22
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 dispensing mechanism includes a drum which is moved horizontally across the target area and counter-rotated to smooth and distribute the powder in an even layer across the target area. A downdraft system provides controlled temperature air flow through the target area to moderate powder temperature during sintering.
Inventors
- 👤 Carl R. Deckard
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 13:26
CPC Classifications
G; G05; G05B; G05B19/00; G05B19/02; G05B19/18; G05B19/41; B; B05; B05C; B05C19/00; B05C19/008; B22; B22F; B22F10/00; B22F10/20; B22F10/28; B22F12/00; B22F12/10; B22F12/60; B22F12/63; B22F12/70; 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; C; C23; C23C; C23C24/00; C23C24/08; C23C24/10; C23C26/00; C23C26/02; B22F10/30; B22F10/36; B22F10/366; B22F10/80; B22F12/40; B22F12/41; B22F12/44; B22F12/49; B22F12/50; B22F12/52; B22F12/57; B22F2003/1052; B22F2998/00; B22F2998/10; B29C35/00; B29C35/02; B29C35/04; B29C35/045; G05B2219/00; G05B2219/30; G05B2219/49; G05B2219/49013; G05B2219/49018; Y; Y02; Y02P; Y02P10/00; Y02P10/25
Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
132 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 dispensing powder into said target area including, a drum, means for moving the drum from one end of the target area to the other end, and means for counter-rotating the drum; means for directing air flow through the target area to moderate powder temperature; 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.
Claim 2
Independent Claim
132 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 dispensing powder into said target area including, a drum, means for moving the drum from one end of the target area to the other end, and means for counter-rotating the drum; means for directing air flow through the target area to moderate powder temperature; 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.
Claim 3
Independent Claim
243 words
A method of producing a part comprising the steps of: depositing a first portion of powder onto a target surface, including the substeps of-- depositing a mound of powder proximate one end of the target surface, moving a counter-rotating drum from said one end of the target surface in the direction of another end to contact the mound and leave a layer of powder between the drum and said one end; 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; inducing air flow to the target surface to moderate the temperature of the sintered and unsintered powder deposited thereon; 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; and depositing successive portions of powder onto the previous sintered layers and sintering a layer of each successive portion to produce a part comprising a plurality of sintered layers.
Claim 4
Independent Claim
243 words
A method of producing a part comprising the steps of: depositing a first portion of powder onto a target surface, including the substeps of-- depositing a mound of powder proximate one end of the target surface, moving a counter-rotating drum from said one end of the target surface in the direction of another end to contact the mound and leave a layer of powder between the drum and said one end; 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; inducing air flow to the target surface to moderate the temperature of the sintered and unsintered powder deposited thereon; 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; and depositing successive portions of powder onto the previous sintered layers and sintering a layer of each successive portion to produce a part comprising a plurality of sintered layers.
Claim 5
Independent Claim
83 words
An apparatus for moderating temperature of a powder being sintered in a target area, comprising: a support defining the target area and including a medium porous to air and a plenum for directing air passing through the medium away from the target area; means for dispensing powder into the target area; means for selectively sintering powder in the target area; means for directing air to the target area; and means for controlling the temperature of the air prior to reaching the target area.
Claim 6
Independent Claim
83 words
An apparatus for moderating temperature of a powder being sintered in a target area, comprising: a support defining the target area and including a medium porous to air and a plenum for directing air passing through the medium away from the target area; means for dispensing powder into the target area; means for selectively sintering powder in the target area; means for directing air to the target area; and means for controlling the temperature of the air prior to reaching the target area.
Claim 7
Dependent Claim
27 words
The apparatus in accordance with claim 3, wherein said directing means comprises a chamber surrounding said target area and a blower fan impelling air into the chamber.
Claim 8
Dependent Claim
30 words
The apparatus in accordance with claim 3, said selective sintering means comprising a directed energy beam and means for controlling the aim of the beam and for modulating the beam.
Claim 9
Dependent Claim
46 words
The apparatus in accordance with claim 3, said dispensing means comprising a drum, means for moving the drum from one end of the target area to the other end, means for counter-rotating the drum, and means for depositing a mound of powder proximate said one end.
Claim 10
Dependent Claim
19 words
The apparatus in accordance with claim 3, said temperature controlling means comprising a heating element disposed in the air.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-05-20 | 1994-11-19 | 1995-05-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-05-20 | 1998-11-19 | 1999-05-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-05-20 | 2002-11-19 | 2003-05-21 | $7700.00 | Window Closed / Lapsed |