US 6,476,343 B2Granted

Energy-beam-driven rapid fabrication system

AssigneeSandia Corporation

InventorsDavid M. Keicher, Clinton L. Atwood, Donald L. Greene, Michelle L. Griffith, Lane D. Harwell, Francisco P. Jeantette, Joseph A. Romero, Lee P. Schanwald, David T. Schmale

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Abstract

An energy beam driven rapid fabrication system, in which an energy beam strikes a growth surface to form a molten puddle thereon. Feed powder is then injected into the molten puddle from a converging flow of feed powder. A portion of the feed powder becomes incorporated into the molten puddle, forcing some of the puddle contents to freeze on the growth surface, thereby adding an additional layer of material. By scanning the energy beam and the converging flow of feed powder across the growth surface, complex three-dimensional shapes can be formed, ready or nearly ready for use. Nearly any class of material can be fabricated using this system.

Claims10

Dependent claims

A system for fabricating an object, comprising:

a) a growth surface;
b) an energy beam directed onto the growth surface, forming thereon a melt-pool comprising a liquid;
c) a delivery system which directs a converging flow of feed powder onto the melt-pool;
d) means for translating the delivery system relative to the growth surface while controlling the rate of flow of feed powder, thereby depositing at least one material layer so as to form the object;
e) an operating chamber containing at least the delivery system, the growth surface, the means for translating, and a processing atmosphere;
and,
f) a waste powder collector system, wherein the waste powder collector system includes a collector and a perforated base plate disposed to allow waste feed powder to enter the collector.

4 more elements

Dependencies are inferred from the claim text.

Facts

Application: 09/066,623Filed 24 Apr 1998 · continuation in part
Priority: 8 Jul 1996
Published: US 2001/0008230 A119 Jul 2001
Granted: 5 Nov 2002
Term ends: Not estimatedThe source records don’t support an estimate.

Classification22 codes

B23K 26/1482
Nozzles; Features related to nozzles: detachable nozzles, e.g. exchangeable or provided with breakaway lines
B01F 33/406
Mixers using gas or liquid agitation, e.g. with air supply tubes: in receptacles with gas supply only at the bottom
B01F 35/714112
Rotating or oscillating about an axis: the measuring chambers being channels extending between both front faces of a rotating cylinder or disc
B22F 10/25
Direct sintering or melting: direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]