System and method for direct fabrication of micro/macro scale objects in a vacuum using electromagnetic steering

A method of fabricating objects in a vacuum chamber, comprising the steps of:

• generating a pressure differential by generating a vacuum at a first predetermined pressure in a first differentially pumped vacuum chamber and generating a vacuum at a second predetermined pressure in a second differentially pumped vacuum chamber;
• propelling particles of a powder in a direction toward a substrate using the pressure differential;
• charging the particles by exposing the particles to ultraviolet light;
• heating the charged particles by exposing the particles to infrared light;
• generating a steering field using an electromagnetic field generating device;
• and
• directing the charged particles toward specific locations on the substrate by adjusting the steering field.

A system for fabricating objects in a vacuum chamber, comprising:

• a container for holding particles of a powder;
• a plurality of differentially pumped vacuum chambers connected to the container and in series for generating a pressure differential to draw the particles out of the container and to propel the particles through a tube connected to the vacuum chambers in a direction toward a substrate;
• a charging lamp connected to the vacuum chambers for charging the particles;
• and
• an electromagnetic field generating device connected to the tube for generating a steering magnetic field, the steering magnetic field adapted to control the direction of charged particles propelled out of the tube.

A system for fabricating objects in a vacuum chamber, comprising:

• a hopper for holding particles in a powder;
• an enclosure containing a plurality of differentially pumped chambers connected to the hopper for drawing the particles out of the hopper and propelling the particles through a tube connected to the enclosure in a direction toward a substrate positioned proximate the tube;
• a charging lamp connected to the enclosure for charging the particles;
• a plurality of heating lamps connected to the tube for heating the charged particles passing through the tube;
• and
• an electromagnetic field generating device connected to a steering portion of the tube for generating a steering magnetic field for use in controlling the direction of the charged particles exiting the steering portion of the tube.