Additive manufacturing by spatially controlled material fusion
Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.
1. An apparatus for additive manufacturing, comprising:
a build surface;
a material depositing system configured to deposit a layer of material onto the build surface;
sources of laser energy configured to expose the layer of material to projections of laser energy; and
an intensity modulator associated with the sources of laser energy,
wherein exposure of the layer of material to the projections of laser energy fuses at least a portion of the layer of material, wherein each of the sources of laser energy is configured to form a line projection having a substantially linear shape, wherein the line projection is achieved by a superposition of the linear sources of laser energy, each having a length that is less than a length of the line projection, and wherein the intensity modulator is configured to independently control intensities of particular regions along the length of the line projection.
2. The apparatus of claim 1 , wherein the build surface is enclosed within a chamber wherein the sources of laser energy are positioned outside of the chamber, and wherein the laser energy passes through a window that is integral with a surface of the chamber.
3. The apparatus of claim 1 , wherein the material depositing system comprises at least one of a powder spreading system, an inkjet deposition system, an electro-hydrodynamic deposition system, and an extrusion nozzle.
4. The apparatus of claim 1 , wherein the material depositing system is configured to deposit at least one of a metallic material, a ceramic material, a polymeric material, and a liquid material.
5. The apparatus of claim 1 , further comprising at least one laser source configured to form a dot projection.
6. The apparatus of claim 1 , wherein the intensity modulator comprises at least one of a grating light valve and a planar light valve modulator.
7. The apparatus of claim 1 , further comprising a second build surface, wherein the sources of laser energy are configured to expose material on each of the build surface and second build surface to the projections of laser energy, and wherein the second build surface is movable relative to the first build surface.
8. The apparatus of claim 1 , further comprising a mirror-based system associated with the sources of laser energy and configured to adjust a position of the projections of laser energy relative to the build surface.
9. The apparatus of claim 1 , further comprising a non-modulated line projection configured to heat at least a portion of the layer of material to a first temperature below the melting temperature of the layer of material, and a modulated line projection configured to heat the portion of the layer of material to a second temperature higher than the melting temperature of the layer of material.
10. An apparatus for additive manufacturing, comprising:
a build surface;
a material depositing system configured to deposit a layer of material onto the build surface;
a first source of laser energy configured to expose the layer of material to a first line projection, the first line projection configured to heat at least a portion of the layer of material to a first temperature below the melting temperature of the layer of material; and
a second source of laser energy configured to expose the layer of material to a second line projection, the second line projection configured to heat the portion of the layer of material to a second temperature higher than the melting temperature of the layer of material,
wherein exposure of the layer of material to the first and second line projections of laser energy fuses at least a portion of the layer of material, wherein each of the first and second sources of laser energy is configured to form a line projection having a substantially linear shape, and wherein the line projection is achieved by a superposition of a plurality of linear sources of laser energy, each having a length that is less than a length of the line projection.
11. The apparatus of claim 10 , wherein the build surface is enclosed within a chamber, wherein the first and second sources of laser energy are positioned outside of the chamber, and wherein the laser energy passes through a window that is integral with a surface of the chamber.
12. The apparatus of claim 10 , wherein the material depositing system comprises at least one of a powder spreading system, an inkjet deposition system, an electro-hydrodynamic deposition system, and an extrusion nozzle.
13. The apparatus of claim 10 , wherein the material depositing system is configured to deposit at least one of a metallic material, a ceramic material, a polymeric material, and a liquid material.
14. The apparatus of claim 10 , further comprising at least one laser source configured to form a dot projection.
15. The apparatus of claim 10 , further comprising an intensity modulator associated with first and second sources of laser energy and wherein the intensity modulator comprises at least one of a grating light valve and a planar light valve modulator.
16. The apparatus of claim 10 , further comprising a second build surface, wherein the first and second sources of laser energy are configured to expose material on each of the build surface and second build surface to the projections of laser energy, and wherein the second build surface is movable relative to the first build surface.
17. The apparatus of claim 10 , further comprising a mirror-based system associated with the first and second sources of laser energy and configured to adjust a position of the first and second line projections of laser energy relative to the build surface.
18. The apparatus of claim 10 , wherein the first line projection is a non-modulated line projection, and wherein the second line projection is a modulated line projection.
19. An apparatus for additive manufacturing, comprising:
a build surface enclosed within a chamber;
a material depositing system configured to deposit a layer of material onto the build surface; and
sources of laser energy positioned outside of the chamber and configured to expose the layer of material to projections of laser energy, wherein the laser energy passes through a window that is integral with a surface of the chamber,
wherein exposure of the layer of material to the projections of laser energy fuses at least a portion of the layer of material, wherein each of the sources of laser energy is configured to form a line projection having a substantially linear shape, and wherein the line projection is achieved by a superposition of the linear sources of laser energy, each having a length that is less than a length of the line projection.
20. The apparatus of claim 19 , wherein the material depositing system comprises at least one of a powder spreading system, an inkjet deposition system, an electro-hydrodynamic deposition system, and an extrusion nozzle.
21. The apparatus of claim 19 , wherein the material depositing system is configured to deposit at least one of a metallic material, a ceramic material, a polymeric material, and a liquid material.
22. The apparatus of claim 19 , further comprising at least one laser source configured to form a dot projection.
23. The apparatus of claim 19 , further comprising an intensity modulator associated with sources of laser energy and wherein the intensity modulator comprises at least one of a grating light valve and a planar light valve modulator.
24. The apparatus of claim 19 , further comprising a second build surface, wherein the sources of laser energy are configured to expose material on each of the build surface and second build surface to the projections of laser energy, and wherein the second build surface is movable relative to the first build surface.
25. The apparatus of claim 19 , further comprising a mirror-based system associated with the sources of laser energy and configured to adjust a position of the projections of laser energy relative to the build surface.
26. The apparatus of claim 19 , further comprising a non-modulated line projection configured to heat at least a portion of the layer of material to a first temperature below the melting temperature of the layer of material, and a modulated line projection configured to heat the portion of the layer of material to a second temperature higher than the melting temperature of the layer of material.