# US 2017/0256385 A1 · Three-Dimensional Plasma Printer

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- Number: US 2017/0256385 A1
- Document ID: US20170256385A1
- Status: Published application
- Kind: A1
- Application number: 15/057,635
- Filed: 2016-03-01
- Published: 2017-09-07
- Earliest claimed: 2016-03-01
- Assignees: KYOCERA Document Solutions Inc.
- Applicants: KYOCERA Document Solutions Inc.
- Inventors: Svetlana Paskalova
- Web page: https://patentgrep.com/patent/US20170256385A1

## CPC

- H01J 37/32926: {Software, data control or modelling}
- B23K 10/027: {Welding for purposes other than joining, e.g. build-up welding}
- B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)}
- B29C 64/159: using only gaseous substances, e.g. vapour deposition
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- H01J 37/32055: {Arc discharge}
- H01J 37/32091: {the radio frequency energy being capacitively coupled to the plasma}
- H01J 37/321: {the radio frequency energy being inductively coupled to the plasma}
- H01J 37/3244: {Gas supply means}
- H01J 37/32458: {Vessel}
- H05H 1/42: with provisions for introducing materials into the plasma, e.g. powder or liquid {(arc stabilising or constricting arrangements H05H1/3405; coaxial protecting fluids H05H1/341)}
- H01J: ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS (spark-gaps H01T; electric arc lamps H05B31/00; particle accelerators H05H)
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- H05H: PLASMA TECHNIQUE (apparatus or processes specially adapted for producing X-rays H05G2/00); PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS

## Abstract

In one aspect, a method is described. The method may include ionizing a plasma gas to generate a plasma in a plasma source and accelerating the plasma toward a work surface. The method may further include adding a material to the plasma, thereby melting the material and accelerating the melted material toward the work surface. The method may further include depositing successive layers of the melted material on the work surface to form a three-dimensional object. Each of the successive layers may correspond to one of a number of planar slices of the three-dimensional object.

## Claims

### Claim 1

A method comprising:
ionizing a plasma gas to generate a plasma in a plasma source;
accelerating the plasma toward a work surface;
adding a material to the plasma, thereby melting the material and accelerating the melted material toward the work surface; and
depositing successive layers of the melted material on the work surface to form a three-dimensional object.

### Claim 2 (depends on 1)

The method of claim 1, wherein depositing successive layers of the melted material on the work surface to form the three-dimensional object comprises:
parsing three-dimensional object data indicative of the three-dimensional object to be printed into cross-section object data indicative of a plurality of planar slices of the three-dimensional object; and
depositing successive layers of the melted printing material on the work surface, each of the successive layers corresponding to one of the plurality of planar slices of the three-dimensional object.

### Claim 3 (depends on 1)

The method of claim 1, wherein the material comprises a material selected from the group consisting of a ceramic powder, a metal powder, and a composite material powder.

### Claim 4 (depends on 1)

The method of claim 1, wherein the material comprises a first powder and a second powder, wherein the first and second powders are blended before adding the material to the plasma.

### Claim 5 (depends on 1)

The method of claim 1, wherein adding the material to the plasma comprises:
fluidizing the material with the carrier gas; and
feeding the fluidized material to the plasma through a liquid-cooled probe.

### Claim 6 (depends on 5)

The method of claim 5, wherein the fluidized material is added to the plasma inside the plasma source.

### Claim 7 (depends on 5)

The method of claim 5, wherein the fluidized material is added to the plasma outside the plasma source into a plasma jet.

### Claim 8 (depends on 5)

The method of claim 5, wherein the liquid-cooled probe comprises a water-cooled probe.

### Claim 9 (depends on 1)

The method of claim 1, further comprising, prior to adding the material to the plasma, exposing the work surface to the plasma to etch the work surface.

### Claim 10 (depends on 1)

The method of claim 1, wherein the plasma comprises inductively coupled plasma.

### Claim 11 (depends on 1)

The method of claim 1, wherein the plasma comprises capacitively coupled plasma.

### Claim 12 (depends on 1)

The method of claim 1, wherein the plasma comprises direct current arc plasma.

### Claim 13 (depends on 1)

The method of claim 1, wherein the plasma has a temperature that is variable between 300 kelvin and 6,000 kelvin.

### Claim 14

A system comprising:
a work surface;
a plasma source configured to generate a plasma by ionizing a plasma gas and to accelerate the plasma toward the work surface;
a feeder configured to add a material to the plasma, wherein the material is melted and accelerated toward the work surface; and
a controller configured to adjust the relative position of the plasma to the work surface to deposit successive layers of the melted material on the work surface.

### Claim 15 (depends on 14)

The system of claim 14, wherein adjusting the relative position of the plasma to the work surface to deposit successive layers of the melted material on the work surface comprises:
parsing three-dimensional object data indicative of a three-dimensional object to be printed into cross-section object data indicative of a plurality of planar slices of the three-dimensional object; and
adjusting the relative position of the plasma to the work surface to deposit successive layers of the melted material on the work surface, each of the successive layers corresponding to one of the plurality of planar slices of the three-dimensional object.

### Claim 16 (depends on 14)

The system of claim 14, wherein the plasma source is further configured to etch the work surface by exposing the work surface to the plasma prior to the feeder adding the material to the plasma.

### Claim 17

A printing head apparatus for fabricating a three-dimensional object comprising:
a first inlet configured to receive a plasma gas;
a plasma source configured to ionize the plasma gas to generate a plasma, wherein the plasma source comprises an anode and cathode configured to generate a direct current arc plasma, a coil configured to generate an inductively coupled plasma, and capacitive electrodes configured to generate a capacitively coupled plasma, wherein the plasma source is configured to accelerate the plasma toward a work surface; and
a second inlet configured to receive a powdered printing material and add the powdered printing material to the plasma, wherein the powdered printing material is melted and deposited on the work surface to form a three-dimensional object.

### Claim 18 (depends on 17)

The apparatus of claim 17, wherein the plasma gas comprises a noble gas.

### Claim 19 (depends on 17)

The apparatus of claim 17, wherein the plasma gas comprises oxygen.

### Claim 20 (depends on 17)

The apparatus of claim 17, wherein the plasma gas comprises a reduced gas.

### Claim 21 (depends on 17)

The apparatus of claim 17, wherein the apparatus is contained within a pressurized housing, wherein the housing is pressurized at a pressure below atmospheric pressure.

### Claim 22 (depends on 17)

The apparatus of claim 17, wherein the apparatus is contained within a pressurized housing, wherein the housing is pressurized at atmospheric pressure.

### Claim 23 (depends on 17)

The apparatus of claim 17, wherein the apparatus is contained within a pressurized housing, wherein the housing is pressurized at a pressure above atmospheric pressure.