Methods for partial sintering of powder to create larger powder particles for additive manufacturing processes

A method for creating a second quantity of sinterable powder particles which have sizes falling within a second size distribution range, from a first quantity of sinterable powder particles having sizes falling within a first size distribution range, and contained within a container, and where the sizes of the second quantity of sinterable powder particles in the second size distribution range are all larger than the sizes of the first quantity of powder particles in the first size distribution range, the method comprising:

• providing an electronic controller;
• using a memory in communication with the electronic controller for storing a plurality of different ones of temperature/time heating profiles for different types of powder particles, the plurality of different temperature/time heating profiles further using a starting dimension of the first quantity of sinterable powder particles;
• using the memory to also store a data file for containing a desired size distribution range for at least one specific type of powder particles;
• using a temperature sensor placed in the first quantity of sinterable powder particles to measure a temperature of the first quantity of sinterable powder particles;
• further using the electronic controller to communicate with the temperature sensor and to receive the temperature signals from the temperature sensor for use in implementing a selected one of the temperature/time heating profiles;
• and
• using a furnace operating as a heating component, for receiving the container and heating the first quantity of sinterable powder particles, the furnace being responsive to the electronic controller and configured to apply a predetermined, temperature/time heating profile including a predetermined temperature ramp-up time period, a predetermined temperature hold time period, and a predetermined cool down period to the first quantity of sinterable powder particles to controllably heat the first quantity of sinterable powder particles using the temperature/time heating profile, to cause partial sintering of ones of powder particles within the first quantity of sinterable powder particles to create a new plurality of powder particles which have an increased dimension.

A method for creating a second quantity of sinterable powder particles which have sizes falling within a second size distribution range, from a first quantity of sinterable powder particles contained within a container and having sizes falling within a first size distribution range, and where the sizes of the powder particles in the second size distribution range are all larger than the sizes of particles in the first quantity of sinterable powder particles falling within the first size distribution range, the method comprising:

• using an electronic controller and a memory in communication with the electronic controller to store a plurality of different temperature/time heating profiles, wherein the memory is configured to store a plurality of different ones of the temperature/time profiles for different types of powder particles;
• further using the memory to store information on each of:
• different types of powder;
• different powder sizes;
• and
• an average starting particle dimension of the first quantity of sinterable powder particles;
• placing a temperature sensor within the first quantity of sinterable powder particles, the electronic controller further being in communication with the temperature sensor and configured to receive temperature signals from the temperature sensor for use in implementing a selected one of different temperature/time heating profiles;
• using a furnace operating as a heating component and being responsive to the electronic controller, to heat the first quantity of sinterable powder particles, the furnace configured to apply the selected one of the different, temperature/time heating profiles, dependent on an average particle dimension of powder particles of the first quantity of sinterable powder particles, and including:
• a predetermined temperature ramp-up time period,
• a predetermined temperature hold time period, and
• a predetermined cool down period, to the first quantity of sinterable powder particles to controllably heat the first quantity of sinterable powder particles using the temperature/time heating profile, to cause partial sintering of ones of the powder particles within the first quantity of sinterable powder particles to create a new plurality of powder particles which each have an increased dimension larger than the second size distribution range;
• using a sieve to separate the new plurality of powder particles from remaining ones of the powder particles;
• and
• using a mill to further process the new plurality of powder particles to break down the new plurality of powder particles such that each one of the new of plurality of powder particles is reduced in dimensions to fall within the second distribution range.