Powder Distribution for Laser Sintering Systems

Patent metadata

Field	Value
Publication number	US-2017008234-A1
Application number	US-201615265998-A
Country	US
Kind code	A1
Filing date	Sep 15, 2016
Priority date	Mar 15, 2013
Publication date	Jan 12, 2017
Grant date	—

Abstract

There is provided improved laser sintering systems that increase the powder density and reduce anomalies of the powder layers that are sintered, that measure the laser power within the build chamber for automatic calibration during a build process, that deposit powder into the build chamber through a chute to minimize dusting, and that scrubs the air and cools the radiant heaters with recirculated scrubbed air. The improvements enable the laser sintering systems to make parts that are of higher and more consistent quality, precision, and strength, while enabling the user of the laser sintering systems to reuse greater proportions of previously used but unsintered powder.

First claim

1 - 9 . (canceled)

10 . A method for laser sintering a three dimensional objects based upon design data and from a sinterable powder, the method comprising:
depositing sinterable powder between a powder distribution device and a part bed; distributing the sinterable powder on the part bed to form a first layer of sinterable powder; causing a return portion of the sinterable powder to be repositioned from opposite the part bed from the powder distribution device to between the part bed and the powder distribution device; and distributing the return portion of the sinterable powder on the part bed to further form the first layer of sinterable powder, wherein both distributing steps are performed before the layer of sinterable powder is substantially laser sintered and a second layer of sinterable powder is distributed.

11 . A method according to claim 10 , wherein causing the return portion of the sinterable powder to be repositioned comprises raising a return powder device after the powder distribution device has moved over the return powder device.

12 . A method according to claim 10 , wherein depositing sinterable powder comprises supplying the sinterable powder through a chute.

13 . A method according to claim 12 , wherein supplying the sinterable powder through a chute further comprises pre-heating the sinterable powder within the chute.

14 . A method according to claim 12 , wherein supplying the sinterable powder through a chute further comprises pre-heating the roller positioned proximate the chute.

15 . A method according to claim 10 , further comprising measuring a powder of a laser beam within the build chamber.

16 - 20 . (canceled)

21 . A method according to claim 10 , wherein distributing the return portion of the sinterable powder comprises increasing the density of the sinterable powder.

22 . A method according to claim 10 , wherein distributing the return portion of the sinterable powder comprises filling gaps within the sinterable powder.

23 . A method according to claim 10 , wherein distributing the return portion of the sinterable powder comprises leveling raised portions of sinterable powder.

24 . A method of applying a single layer of sinterable powder for a laser sintering system, the method comprising:
depositing sinterable powder between a powder distribution device and a part bed; distributing the sinterable powder on the part bed in a first pass; causing a return portion of the sinterable powder to be repositioned from opposite the part bed from the powder distribution device to between the part bed and the powder distribution device; and increasing the density of the single layer of sinterable powder in a second pass, wherein the second pass is in an opposite direction of the first pass.

25 . A method according to claim 24 , wherein increasing the density of the single layer of sinterable powder comprises filling gaps within the single layer of sinterable powder.

26 . A method according to claim 24 , wherein increasing the density of the single layer of sinterable powder comprises leveling raised portions of powder of the single layer of sinterable powder.

27 . A method according to claim 24 , further comprising depositing residual powder into a powder return shoot after the second pass.

Assignees

• 3D Systems Inc

Inventors

• Cullen David H
• Hidalgo Rafael Enrique

Classifications

• B29C64/205

  Means for applying layers · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F10/73

  of powder · CPC title

• B22F12/20

  Cooling means · CPC title

• B22F12/52

  Hoppers · CPC title