Methods and systems for condensing a vapor on a powder bed
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.
1. 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 produce a dry vapor; and
a vapor deposition subsystem configured to deliver the dry vapor to a surface of the powder bed, wherein at least a portion of the vapor deposition subsystem is moveable relative to the powder bed to deposit the dry vapor.
2. The system of claim 1 , wherein the vapor generator includes at least one of a boiler, a heated surface, a heating coil, or an atomizing nozzle.
3. The method of claim 1 , further comprising a vapor distribution subsystem configured to distribute the dry vapor across the deposition subsystem.
4. The system of claim 3 , wherein the vapor distribution subsystem includes at least one of a branching distribution system or a plenum space.
5. The system of claim 1 , wherein the vapor deposition subsystem includes at least one of an orifice plate, a nozzle, or a plenum space.
6. The system of claim 1 , 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.
7. 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 produce a dry 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.
8. The system of claim 7 , further comprising a valve configured to control a flow of the dry vapor.
9. The system of claim 7 , 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.
10. The system of claim 7 , further comprising a branching distribution system fluidly connected to the plenum space.
11. The system of claim 7 , further comprising a piston system fluidly coupled to the boiler.
12. The system of claim 7 , wherein the nozzle includes an orifice plate.
13. The system of claim 1 wherein vapor generator is configured to control a flow of the vapor by adjusting a pressure in the vapor generator.
14. The system of claim 1 wherein vapor generator is configured to control a flow of the vapor by adjusting a temperature in the vapor generator.
15. The system of claim 7 wherein boiler is configured to control of a flow of the vapor by adjusting a pressure in the boiler.
16. The system of claim 7 wherein boiler is configured to control of a flow of the vapor by adjusting a temperature in the boiler.