Electrostatic particle spreader for powder bed fusion additive manufacturing

A powder particle deposition system for use with a powder bed fusion additive manufacturing system, for moving powder particles without physical contact to recreate a powder bed that is acted on by the powder bed fusion additive manufacturing system, the powder particle deposition system comprising:

• a powder particle container having a bottom wall, and forming a first electrode;
• a second electrode spaced apart from the powder particle container and arranged at an angle of between 5 degree to 70 degrees relative to non-parallel to the powder particle;
• a conducting mesh, which forms a portion of the first electrode, and which extends laterally of the powder particle container and non-parallel to the second electrode;
• a signal source for applying an electrical signal across the first and second electrodes to create an electric field that extends between the first electrode and both of the second electrode and the conducting mesh, the electric field varying in strength along the counter electrode such that the electric field is greatest between the second electrode and the conducting mesh;
• and
• a movement mechanism for moving the powder container and the second electrode over a powder bed, the powder particles being caused by the electric field to move out from the powder container, toward the second electrode, and then to be repelled from the second electrode and to fall toward the conducting mesh, wherein at least a portion of the particle powders falling toward the conducting mesh fall through the conducting mesh onto the powder bed as the movement mechanism is moved over the powder bed.

A powder particle deposition method for use with a powder bed fusion additive manufacturing system, for moving powder particles without physical contact to recreate a powder bed, the powder particle deposition method comprising:

• using a powder particle container to form a first electrode;
• placing a second electrode spaced apart from the powder particle container and arranged non-parallel to the powder particle;
• using a signal source to apply an electrical signal across the first and second electrodes to create an electric field between the first and second electrodes, the electric field varying in strength such that the electric field is stronger at one side of the powder particle container;
• and
• using the electric field to move powder particles out from the powder container, toward the second electrode, wherein the powder particles are then repelled from the second electrode and fall onto the powder bed.