Granted Patent B2

US 12,251,884 · App. 15/582,409 · Granted Mar 18, 2025

Inventors: Eahab Nagi El Naga (Topanga, CA); John Russell Bucknell (El Segundo, CA); Chor Yen Yap (Gardena, CA); Broc William TenHouten (Rancho Palos Verdes, CA); Antonio Bernerd Martinez (El Segundo, CA)

Assignee: DIVERGENT TECHNOLOGIES, INC.

B29C64/40B22F3/02B22F3/1017B22F3/164B22F3/18B22F10/28B22F10/43B22F10/47B22F10/60B22F10/66B23K26/142B23K26/342B23K26/702B29C64/386B33Y10/00B33Y30/00B33Y50/02B22F10/30B22F12/55B22F12/60B22F2202/01B22F2202/06B22F2998/10B22F2999/00

Abstract

Claims (22)

1. An apparatus for powder-bed fusion, comprising:

a depositor configured to deposit a plurality of layers of a powder material, the depositor configured to move across a work area of a powder bed to deposit each of the plurality of layers;

an energy beam source that generates an energy beam;

a heater press that at least partially sinters and compacts the powder material in a first area in a first one of the layers; and

a deflector that applies the energy beam to fuse the powder material in a second area in a second one of the layers, wherein the first area is underneath at least a portion of an overhang area of a build piece and above a region of unfused and unbound powder.

2. The apparatus of claim 1 , further comprising a support structure, coupled to the powder material in the first area in the first one of the layers.

3. The apparatus of claim 1 , wherein the heater press is configured to move across the work area following the depositor.

4. The apparatus of claim 1 , wherein the at least partially sintered powder material does not form an attachment to the build piece.

5. The apparatus of claim 1 , wherein the at least partially sintered powder material is further under at least a portion of an overhang of another component.

6. An apparatus for powder-bed fusion, comprising:

a depositor configured to deposit a plurality of layers of a powder material, the depositor configured to move across a work area of a powder bed to deposit each of the plurality of layers;

an energy beam source that generates an energy beam;

a heater press that at least partially sinters and compacts the powder material in a first area in a first one of the layers;

a deflector that applies the energy beam to fuse the powder material in a second area in a second one of the layers, wherein the first area is underneath at least a portion of an overhang area of a build piece and above a region of unfused and unbound powder; and

a support structure, coupled to the powder material in the first area in the first one of the layers.

7. An apparatus for powder-bed fusion, comprising:

a depositor configured to deposit a plurality of layers of a powder material, the depositor configured to move across a work area of a powder bed to deposit each of the plurality of layers;

an energy beam source that generates an energy beam;

a heater press that at least partially sinters the powder material in a first area in a first one of the layers, and the heater press is configured to compact the powder material in the first area; and

a deflector that applies the energy beam to fuse the powder material in a second area in a second one of the layers, wherein the first area is underneath at least a portion of an overhang area of a build piece and above a region of unfused and unbound powder, and wherein the at least partially sintered powder material is further under at least a portion of an overhang of another component.

8. The apparatus of claim 1 , wherein the first area extends to an area not under the overhang area.

9. The apparatus of claim 2 , wherein the support structure includes an attachment to a portion of the build piece outside the overhang area.

Assignments (5)

Continuity (1)

References Cited (400)