Additive manufacturing system for object creation from powder using a high flux laser for two-dimensional printing
A method of additive manufacture is disclosed. The method can include providing an enclosure surrounding a powder bed and having an atmosphere including helium gas. A high flux laser beam is directed at a defined two dimensional region of the powder bed. Powder is melted and fused within the defined two dimensional region, with less than 50% by weight of the powder particles being displaced into any defined two dimensional region that shares an edge or corner with the defined two dimensional region where powder melting and fusing occurs.
1 . A method of additive manufacture, comprising:
providing an enclosure surrounding a powder bed and having an atmosphere including at least 1% helium gas at greater than atmospheric pressure;
directing a laser beam having a flux greater than 100 megawatts/square centimeter at a defined two-dimensional region of the powder bed; and
printing an object by melting and fusing powder within the defined two-dimensional region,
wherein less than a threshold percentage of the powder in the defined two-dimensional region is displaced into another two-dimensional region that shares an edge or corner with the defined two-dimensional region,
wherein the printing is conducted with the atmosphere in an initial pressure range and is intermittently paused with the atmosphere in an increased pressure range with an elevated temperature range.
2 . The method of claim 1 , wherein the atmosphere further comprises at least one of Ar, Ne, Kr, Xe, CO 2 , N 2 , O 2 , SF 6 , CH 4 , CO, N 2 O, C 2 H 2 , C 2 H 4 , C 2 H 6 , C 3 H 6 , C 3 H 8 , i-C 4 H 10 , C 4 H 10 , 1-C 4 H 8 , cic-2, C 4 H 7 , 1,3-C 4 H 6 , 1,2-C 4 H 6 , C 5 H 12 , i-C 5 H 12 , n-C 6 H 14 , C 2 H 3 Cl, C 7 H 16 , C 8 H 18 , C 10 H 22 , C 11 H 24 , C 12 H 26 , C 13 H 28 , C 14 H 30 , C 15 H 32 , C 16 H 34 , C 6 H 6 , C 6 H 5 -CH 3 , C 8 H 10 , C 2 H 5 OH, CH 3 OH, and iC 4 H 8 .
3 . The method of claim 1 , wherein the helium keeps vapor generated by the laser beam heating the powder from being super-heated and push powder out of the defined two-dimensional region.
4 . The method of claim 1 , wherein the helium is used to ensure that less than 10% by mass of the powder in the defined two-dimensional region is displaced into another two-dimensional region that shares an edge or corner with the defined two-dimensional region.
5 . The method of claim 1 , wherein the initial pressure range comprises 0.0001 bar to 1.0 bar and the increased pressure range comprises 500 bar to 1000 bar.
6 . The method of claim 5 , wherein in the elevated temperature range comprises 400° C. to 1500° C.
7 . A method of additive manufacture, comprising:
providing an enclosure surrounding a powder bed and having an atmosphere including at least 50% helium gas at less than atmospheric pressure;
directing a laser beam having a flux greater than 100 megawatts/square centimeter at a defined two-dimensional region of the powder bed; and
printing an object by melting and fusing powder within the defined two-dimensional region,
wherein less than a threshold percentage of the powder in the defined two-dimensional region is displaced into another two-dimensional region that shares an edge or corner with the defined two-dimensional region,
wherein the printing is conducted with the atmosphere in an initial pressure range and is intermittently paused with the atmosphere in an increased pressure range with an elevated temperature range.
8 . The method of claim 7 , wherein the atmosphere further comprises at least one of Ar, Ne, Kr, Xe, CO 2 , N 2 , O 2 , SF 6 , CH 4 , CO, N 2 O, C 2 H 2 , C 2 H 4 , C 2 H 6 , C 3 H 6 , C 3 H 8 , i-C 4 H 10 , C 4 H 10 , 1-C 4 H 8 , cic-2, C 4 H 7 , 1,3-C 4 H 6 , 1,2-C 4 H 6 , C 5 H 12 , i-C 5 H 12 , n-C 6 H 14 , C 2 H 3 Cl, C 7 H 16 , C 8 H 18 , C 10 H 22 , C 11 H 24 , C 12 H 26 , C 13 H 28 , C 14 H 30 , C 15 H 32 , C 16 H 34 , C 6 H 6 , C 6 H 5 -CH 3 , C 8 H 10 , C 2 H 5 OH, CH 3 OH, and iC 4 H 8 .
9 . A method of additive manufacture, comprising:
providing an enclosure surrounding a powder bed and having an atmosphere including at least 1% helium gas heated to greater than 20 degrees Celsius;
directing a laser beam having a flux greater than 100 megawatts/square centimeter at a defined two-dimensional region of the powder bed; and
printing an object by melting and fusing powder within the defined two-dimensional region,
wherein less than a threshold percentage of the powder in the defined two-dimensional region is displaced into another two-dimensional region that shares an edge or corner with the defined two-dimensional region,
wherein the printing is conducted with the atmosphere in an initial pressure range and is intermittently paused with the atmosphere in an increased pressure range with an elevated temperature range.
10 . The method of claim 9 , wherein the atmosphere further comprises at least one of Ar, Ne, Kr, Xe, CO2, N 2 , O 2 , SF 6 , CH 4 , CO, N 2 O, C 2 H 2 , C 2 H 4 , C 2 H 6 , C 3 H 6 , C 3 H 8 , i-C 4 H 10 , C 4 H 10 , 1-C 4 H 8 , cic-2, C 4 H 7 , 1,3-C 4 H 6 , 1,2-C 4 H 6 , C 8 H 12 , i-C 8 H 12 , n-C 6 H 14 , C 2 H 3 Cl, C 7 H 16 , C 8 H 18 , C 10 H 22 , C 11 H 24 , C 12 H 26 , C 13 H 28 , C 14 H 30 , C 15 H 32 , C 16 H 34 , C 6 H 6 , C 6 H 5 -CH 3 , C 8 H 10 , C 2 H 5 OH, CH 3 OH, and iC 4 H 8 .