Method and apparatus for producing parts by selective sintering

A method of forming an integral three-dimensional object, comprising the steps of:

• positioning a target in proximity to means for storing and supplying a powder material;
• depositing a quantity of said powder material into the area of the target;
• utilizing means for directing an energy beam into the target area to change a property of at least part of said quantity of powder material to form a layer;
• and
• repeating said depositing and utilizing steps to form a plurality of said layers;
• each of said layers being integrally bonded to the next adjacent of said layers by said utilizing steps to form an integral three-dimensional object.

An apparatus for producing a part comprising:

• means for producing a directed energy beam;
• a powder dispenser having an outlet directed to a target area;
• means for directing the beam to the target area and for scanning the target area with the aim of the beam in a repetitive pattern;
• means for controlling the operation of the beam means to selectively sinter powder dispensed in the target area during the scanning pattern, including
• computer means operatively coupled to the directing means to monitor the aim of the laser beam during the scanning pattern,
• the computer means being programmed with information indicative of the desired boundaries of a plurality of cross-sectional regions of the part being produced,
• The computer means being operable for modulating the beam means when the aim of the beam is within the desired boundaries of the first cross-sectional region to sinter a first layer of powder in the target area,
• and for modulating the beam means when the aim of the beam is within the desired boundaries of the second cross-sectional region to sinter a second layer of powder and to join the first and second layers of powder,
• and for modulating the beam means when the aim of the beam is within succeeding desired boundaries of succeeding cross-sectional regions to sinter succeeding layers of powder and to join the sintered layers to form said part.

An apparatus for producing a part comprising:

• laser means for selectively emitting a laser beam;
• structure for providing a target area for producing the part;
• means for dispensing powder into said target area;
• and
• laser control means responsive to a plurality of defined boundaries in which at least some of the boundaries are different for --
• moving the aim of the laser beam across the target area,
• modulating the laser to selectively sinter a first layer of powder dispensed within a first defined boundary in the target area,
• modulating the laser to selectively sinter subsequent layers of powder dispensed within respective defined boundaries to produce a part comprising a plurality of sintered layers joined together.