Catalyst and plasma assisted nucleation and renucleation of gas phase selective laser deposition

A method of depositing a layer of material onto a substrate, comprising:

• providing a substrate having an upper surface layer;
• preparing a catalytic composition upon a portion of said surface layer;
• scanning an energy beam across said surface layer;
• growing material from said gas phase onto said surface layer at select scan locations of said beam, said material is grown in a substantially uniform pattern at said locations.

A method of depositing a layer of material, comprising:

• providing a part having an outer layer;
• positioning a gas phase proximate said outer layer;
• introducing a catalyst gas into said gas phase;
• scanning an energy beam across said outer layer;
• and
• depositing material from said gas phase onto said outer layer at select scan locations of said beam, said material being deposited in a substantially uniform pattern at said locations in accordance with concentration of the catalytic gas within said gas phase.

A method of producing a part upon a substrate, comprising:

• providing a sealable chamber;
• placing a substrate within said sealable chamber, said substrate having an outer surface layer;
• preparing a catalytic composition upon a portion of said surface layer;
• introducing a gas phase into said sealable chamber and proximate said surface layer;
• scanning an energy beam across said surface layer;
• introducing a catalyst gas into said sealable chamber and within said gas phase;
• scanning said energy beam across said surface layer;
• depositing material from said gas phase onto said surface layer in a three dimensional growth pattern at select scan locations of said beam, said material is deposited in a substantially uniform pattern at said locations in accordance with concentration of the catalyst gas and the catalytic composition;
• and
• repeating the last three steps to deposit successive layers of materials comprising said part.

An apparatus for producing a part, comprising:

• a gas-filled chamber;
• a target area within said chamber;
• a catalyst formed upon said target area;
• and
• at least one energy beam directed upon said target area to selectively nucleate and renucleate said gas upon said target area to form a part.