Laser sintering powder recycle system
Assignee3D Systems, Inc.
InventorBrian Cox
Life of this patent
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Abstract
A method and apparatus for forming three-dimensional objects by laser sintering that includes the use of dense phase pneumatic conveying to internally recycle overflow powder, and to thoroughly blend overflow, recovered and virgin powder to provide a consistent powder feed mix to a laser sintering machine. Overflow powder from the laser sintering machine is recovered and recycled back into the laser sintering machine for reuse. The approach results in a compact and reliable powder recycle system with complete blending and minimum attrition to the handled powder.
Claims45
An apparatus for producing three-dimensional articles from a powder comprising:
- (a) a chamber within the apparatus in which a layerwise build process is performed to produce three-dimensional objects, the chamber having a first side and an opposing second side;
- (b) a powder feed hopper, located on the first side of the chamber for depositing a quantity of powder into the chamber;
- (c) a spreader, located adjacent the feed hopper, for spreading the quantity of powder in the chamber;
- (d) a receiving device for receiving overflow powder delivered by the spreader, the receiving device being located adjacent at least one side of the process chamber;
- and
- (e) a pneumatic conveying device in flow communication with the receiving device for returning the overflow powder to the powder feed hopper.
The apparatus of claim 21 wherein the blender storage vessel blends by circulating powder through the blender storage vessel.
The apparatus of claim 22 wherein the circulation of powder through the blender storage vessel is conveyed by a pneumatic dense phase conveying device.
A method for producing a bed of powder in a laser sintering machine in which a three-dimensional article is formed in layerwise fashion comprising the steps of:
- (a) depositing a first portion of powder from a feed hopper in a process chamber across a target area from a first side to an opposing second side;
- (b) collecting excess of the first portion of powder as overflow on the opposing second side of the target area;
- (c) scanning a laser beam across the first portion of powder in the target area to selectively fuse a layer of powder in a desired cross-section;
- (d) depositing a second portion of powder across the target area on the process chamber from the second side to the first side;
- (e) collecting excess of the second portion of powder as overflow on the first side of the target area;
- (f) scanning a laser beam across the second portion of powder in the target area to selectively fuse a subsequent layer of powder in a desired cross-section;
- and
- (g) pneumatically conveying the overflow from the first side and the second side of target area back to the feed hopper.
Dependencies are inferred from the claim text.