Thermal management system for a removable build chamber for use with a laser sintering system

1. A method for controlling the temperature of a build chamber used in a laser sintering system comprising the steps of:

a. connecting a first build chamber to a thermal management station to preheat the build chamber to a temperature at or near an operating temperature of the laser sintering system;

b. disconnecting the build chamber from the thermal management station and inserting it into the laser sintering system;

c. operating the laser sintering system to complete a build by forming at least one part in a part cake comprised of fused and unfused powder;

d. removing the build chamber from the laser sintering system;

e. connecting the removed build chamber to thermal management station; and

f. controlling the cool down of the build chamber, by monitoring the temperature of the part cake at selected locations about the periphery of the part cake, to lower the temperature of the build chamber and the part cake to a temperature to permit breakout and removal of the at least one part in the part cake.

2. The method according to claim 1 further comprising preheating a replacement build chamber prior to removing the first build chamber from the laser sintering system.

3. The method according to claim 1 further comprising inserting the build chamber into a process chamber within the laser sintering system.

4. The method according to claim 1 further comprising controlling the cool down of the part cake by selectively supplying heat to the build chamber to controllably lower the temperature of the part cake and the at least one part therein to prevent thermal distortion in the at least one part.

5. The method according to claim 1 further comprising monitoring the temperature of the part cake via thermistors in heater bands arranged about a build cylinder containing the part cake within the build chamber.