Gas phase selective beam deposition

A method of producing a part comprising the steps of:

• positioning a plurality of gas phases proximate a target area;
• scanning the aim of at least one directed energy beam relative to said target area and selectively depositing material from said gas phases in a first layer on said target area;
• scanning the aim of at least one directed energy beam across said target area and selectively depositing material from said gas phases in a second layer on said target area, including the substeps of
• joining said first and second layers during the scanning and depositing of the second layer;
• and
• successively scanning the aim of at least one directed energy beam across said target area and selectively depositing material to produce successive layers joined to a previously deposited layer and producing a part comprising a plurality of joined layers.

A method of producing a part comprising the steps of:

• positioning a first gas phase proximate a surface;
• controlling the temperature of said surface and enabling a portion of said first gas phase to condense in a first layer on said surface;
• scanning the aim of at least one first directed energy beam relative to said surface and selectively evaporating material from said first layer;
• positioning a second gas phase proximate said surface;
• controlling the temperature of said surface and enabling a portion of said second gas phase to condense on said first layer;
• scanning the aim of said at least one first directed energy beam across said surface and selectively evaporating material from said second layer
• including the substeps of
• joining the first and second layers during the condensing and scanning of the second layer;
• and
• positioning successive gas phases proximate said surface, controlling the temperature of said surface and enabling a portion of said successive gas phases to condense and join in successive layers on said surface, and scanning the aim of at least one first directed energy beam across said surface and selectively evaporating layers of said material and producing a part comprising a plurality of joined layers.

A method of producing a part comprising the steps of:

• positioning a first gas phase proximate a surface;
• controlling the temperature of said surface and enabling a portion of said first gas phase to condense in a first layer on said surface;
• scanning the aim of at least one first directed energy beam relative to said surface and selectively transforming material in said first layer into a material having a higher melting temperature than said condensed first gas phase material;
• positioning a second gas phase proximate said surface;
• controlling the temperature of said surface and enabling a portion of said second gas phase to condense on said first layer;
• scanning the aim of said at least one first directed energy beam across said surface and selectively transforming material in said second layer into a material having a higher melting temperature than said condensed second gas phase material;
• including the substeps of
• joining the first and second layers during the condensing and scanning of the second layer;
• and
• positioning successive gas phases proximate said surface, controlling the temperature of said surface and enabling a portion of said successive gas phases to condense and join in successive layers on said surface, and scanning the aim of at least one first directed energy beam across said surface and selectively transforming layers of said material and producing a part comprising a plurality of joined layers.

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

• positioning a target in a chamber substantially able to contain a gas phase;
• introducing said gas phase into said chamber;
• utilizing means for directing an energy beam into the target area to change a property of at least part of said gas phase to deposit a layer of material;
• 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:

• a chamber housing a target area;
• means for introducing a gas phase into said chamber;
• means for selectively producing at least one directed energy beam;
• means for directing said beam to said target area and for scanning said target area with the aim of said beam in a selective pattern;
• means for controlling the operation of said beam to selectively deposit material from said gas phase on said target area during said scanning pattern, including
• computer means operatively coupled to the directing means to monitor the aim of said beam during the scanning pattern;
• said computer means being programmed with information indicative of the desired boundaries of a plurality of cross-sectional regions of said part;
• said computer means being operable for modulating said beam when the aim of said beam is within the desired boundaries of the first cross-sectional region to deposit a first layer of material in said target area,
• and for modulating said beam when the aim of said beam is within the desired boundaries of the second cross-sectional region to deposit a second layer of material and join said first and second layers of material,
• and for modulating said beam when the aim of said beam is within succeeding desire boundaries of succeeding cross-sectional regions to deposit succeeding layers of material and join said layers to form said part.