System And Method For High Power Diode Based Additive Manufacturing

Patent metadata

Field	Value
Publication number	US-2016129503-A1
Application number	US-201614988190-A
Country	US
Kind code	A1
Filing date	Jan 5, 2016
Priority date	Mar 5, 2013
Publication date	May 12, 2016
Grant date	—

Abstract

A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

First claim

What is claimed is:

1 . A method for performing Additive Manufacturing (AM) comprising:
irradiating a powdered layer of a substrate using a pulsed optical signal sufficient to irradiate at least a substantial portion of an entire two dimensional area within which the substrate is positioned; using a mask to selectively rotate and block portions of the pulsed optical signal from reaching the first layer of the substrate, wherein the mask absorbs substantially no optical energy from the optical signal as the optical signal passes therethrough; placing a second layer of powdered material over the first layer; and irradiating the second layer using the pulsed optical signal while using the mask to selectively block additional portions of the pulsed optical signal from reaching the second layer of the substrate.

2 . The method of claim 1 , wherein the irradiating a powdered layer of a substrate using a pulsed optical signal comprises using a pulsed diode array to generate the pulsed optical signal.

3 . The method of claim 2 , wherein the using the pulsed diode array comprises using a pulsed diode array configured to generate a power density of at least about 10 kW/cm 2 .

4 . The method of claim 1 , wherein the using a mask to selectively block portions of the pulsed optical signal comprises using a digitally electronically addressable mask.

5 . The method of claim 4 , wherein the using a digitally electronically addressable mask comprises:
using a liquid crystal module to rotate first portions of the pulsed optical signal while allowing second portions of the optical signal to pass therethrough in an unrotated condition; and using a polarizing element downstream of the liquid crystal module to reject a selected one of the first or second portions, and thus impede the selected one of the first or second portions from reaching the substrate.

6 . The method of claim 4 , further comprising using a computer to control the digitally electronically addressable mask.

7 . The method of claim 2 , further comprising using a computer to control the pulsed diode array.

8 . The method of claim 1 , further comprising using a movable, electronically addressable spray source to deposit at least two different material types to form at least one of the first and second layers.

9 . The method of claim 8 , further comprising controlling the mask in accordance with the at least two different material types being irradiated.

10 . A method for performing Additive Manufacturing (AM) comprising:
generating an optical signal toward a powdered material forming a substrate, wherein the optical signal is sufficient to irradiate an entire two dimensional area of the substrate; using a liquid crystal polarization rotator to receive the optical signal before the optical signal reaches the substrate; controlling the liquid crystal polarization rotator to act as a mask by:
controlling a first component of the liquid crystal polarization rotator to rotate a first portion of the optical signal passing therethrough while allowing a second portion of the optical signal to pass therethrough without being rotated; and
controlling a second component of the liquid crystal polarization rotator to reject one of the first or second portions of the optical signal received from the first component, and thus to prevent the one of the first or second portions of the optical signal from reaching the powdered material, while the second component allows the other one of the first or second portions of the optical signal to reach the powdered material.

11 . The method of claim 10 , wherein controlling a first component of the liquid crystal polarization rotator to receive and to rotate a first portion of the optical signal comprises using a liquid crystal module.

12 . The method of claim 10 , wherein controlling a second component of the liquid crystal polarization rotator to reject one of the first or second portions of the optical signal comprises using a polarizer.

13 . The method of claim 10 , wherein the operation of generating an optical signal comprises generating a pulsed optical signal.

14 . The method of claim 10 , wherein the operation of generating an optical signal comprises using a diode array.

15 . The method of claim 11 , wherein the operation of using a liquid crystal module comprises using a computer controllable liquid crystal module.

16 . The method of claim 12 , wherein the operation of using a polarizer comprises using a polarization mirror.

17 . The method of claim 10 , wherein the operation of generating an optical signal comprises using a diode array to generate a pulsed optical signal.

18 . The method of claim 10 , further comprising:
providing the powdered material as a first material type; providing an additional powdered material as a second material type different from the first material type; using a movable, electronically addressable spray source to sequentially deposit the first and second material types to form first and second layers; and further controlling operation of the mask depending on the first and second material types to melt each of the first and second material types.

19 . A method for performing Additive Manufacturing (AM) comprising:
using a laser diode to generate an optical signal toward a first layer of powdered material forming a substrate, wherein the optical signal is sufficient to irradiate an entire two dimensional area of the powdered material; using a liquid crystal polarization rotator to receive the optical signal before the optical signal reaches the first layer of powdered material; controlling the liquid crystal polarization rotator to act as a mask by:
controlling a first component of the liquid crystal polarization rotator to rotate a first portion of the optical signal passing therethrough while allowing a second portion of the optical signal to pass therethrough without being rotated;
controlling a second component of the liquid crystal polarization rotator to reject one of the first or second portions of the optical signal received from the first component, and thus to prevent the one of the first or second portions of the optical signal from reaching the first layer of powdered material, while the second component allows the other one of the first or second portions of the optical signal to reach the first layer of powdered material and to melt the first layer of powdered material;
subsequent to melting of the first layer of powdered material, applying a second layer of powdered material on at least a portion of the first layer of powdered material; and using the laser diode and the liquid crystal polarization rotator to melt at least a portion of the second layer of powdered material.

20 . The method of claim 19 , further comprising using a computer to control the liquid crystal polarization rotator.

Assignees

• L Livermore Nat Security Llc

Inventors

• El-Dasher Bassem S
• Bayramian Andrew
• Demuth James A
• Farmer Joseph C
• Torres Sharon G

Classifications

• B22F10/20

  Direct sintering or melting · CPC title

• B22F10/30

  Process control · CPC title

• B22F12/55

  Two or more means for feeding material · CPC title

• B22F12/44

  characterised by the configuration of the radiation means · CPC title

• B22F12/43

  pulsed; frequency modulated · CPC title