Methods and systems for condensing a vapor on a powder bed

Patent metadata

Field	Value
Publication number	US-2021008617-A1
Application number	US-202016924872-A
Country	US
Kind code	A1
Filing date	Jul 9, 2020
Priority date	Jul 10, 2019
Publication date	Jan 14, 2021
Grant date	—

Abstract

A method is provided for printing a three-dimensional object. The method comprises, depositing a layer of metal powder onto a powder bed of a three-dimensional printer. A liquid is heated to generate a vapor. The liquid is removed from the vapor to dry the vapor by heating the vapor above a condensation temperature of the liquid. The dry vapor is deposited onto the powder bed of the three-dimensional printer.

First claim

What is claimed is:

1 . A method for printing a three-dimensional object, the method comprising:
depositing a layer of metal powder onto a powder bed of a three-dimensional printer; heating a liquid to generate a vapor; removing the liquid from the vapor to dry the vapor by heating the vapor above a condensation temperature of the liquid; and depositing the dry vapor onto the powder bed of the three-dimensional printer.

2 . The method of claim 1 , further comprising controlling a flow of the vapor prior to depositing the vapor.

3 . The method of claim 1 , wherein the dry vapor is flowed through a branching distribution system prior to being deposited onto the powder bed.

4 . The method of claim 1 , wherein the dry vapor is flowed through a plenum space prior to being deposited onto the powder bed.

5 . The method of claim 1 , wherein the liquid is water.

6 . The method of claim 1 , further comprising introducing a carrier gas to the dry vapor.

7 . The method of claim 6 , wherein the carrier gas is at least one of nitrogen or air.

8 . The method of claim 1 , further comprising:
depositing a subsequent layer of metal powder onto the powder bed of the three-dimensional printer; and depositing the dry vapor onto the powder bed of the three-dimensional printer.

9 . A system for printing a three-dimensional object, the system comprising:
a powder bed configured to receive one or more layers of metal powder; a vapor generator configured to heat a liquid to form a vapor; a drying subsystem configured to heat the vapor to remove the liquid from the vapor to dry the vapor; and a vapor deposition subsystem configured to deliver the dry vapor to a surface of the powder bed.

10 . The system of claim 9 , wherein the vapor generator includes at least one of a boiler, a heated surface, a heating coil, or an atomizing nozzle.

11 . The method of claim 9 , further comprising a vapor distribution subsystem configured to distribute the dry vapor across the deposition subsystem.

12 . The system of claim 11 , wherein the vapor distribution subsystem includes at least one of a branching distribution system or a plenum space.

13 . The system of claim 9 , wherein the vapor deposition subsystem includes at least one of an orifice plate, a nozzle, or a plenum space.

14 . The system of claim 9 , wherein the vapor deposition subsystem includes a pair of parallel plates spaced apart from one another to form a gap, wherein a first of the pair of parallel plates defines a plurality of openings, and wherein a second of the pair of parallel plates has a first surface facing the first parallel plate and a second surface adjacent to a plenum space.

15 . A system for printing a three-dimensional object, the system comprising:
a powder bed configured to receive one or more layers of metal powder; a boiler configured to heat a liquid to form a vapor; a heater for heating the vapor to remove the liquid from the vapor to dry the vapor; a diffuser fluidly coupled to a plenum space; and a nozzle fluidly coupled to the plenum space and configured to deliver the dry vapor to the powder bed.

16 . The system of claim 15 , further comprising a valve configured to control a flow of the dry vapor.

17 . The system of claim 15 , wherein the nozzle includes a pair of parallel plates spaced apart from one another to form a gap, wherein a first of the pair of parallel plates defines a plurality of openings, and wherein a second of the pair of parallel plates has a first surface facing the first parallel plate and a second surface adjacent to the plenum space.

18 . The system of claim 15 , further comprising a branching distribution system fluidly connected to the plenum space.

19 . The system of claim 15 , further comprising a piston system fluidly coupled to the boiler.

20 . The system of claim 15 , wherein the nozzle includes an orifice plate.

Assignees

• Desktop Metal Inc

Inventors

• Sachs Emanuel M
• Hoisington Paul A
• Fontana Richard Remo
• Go Jamison
• Johnson Joseph
• Hudelson George
• Lockwood Cassia
• Goldblatt Michael

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title

• B22F12/70

  Gas flow means · CPC title

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title