Additive manufacturing systems and methods
An additive manufacturing method includes patterning a laser beam using a mirror array; and reflecting the patterned laser beam from the mirror array onto a powder to melt the powder, wherein the pattern corresponds to a portion of a layer of an article.
1. An additive manufacturing method, comprising:
patterning a laser beam using a mirror array; and
reflecting the patterned laser beam from the mirror array onto a powder to melt the powder, wherein the pattern corresponds to a portion of a layer of an article, wherein the patterned laser beam comprises a plurality of laser spots, groups of 9-25 mirrors are configured to provide each laser spot of the patterned laser beam, a power capacity of each mirror is 1 to 3 watts, and the groups of mirrors are configured to provide laser spots of 10 to 25 watts.
2. A method according to claim 1 , further comprising:
spreading a layer of powder over the layer of the article after solidification of the layer of the article.
3. A method according to claim 2 , further comprising:
adjusting a position of a build table that supports the article.
4. A method according to claim 1 , further comprising:
providing a desired distribution profile to the laser beam.
5. A method according to claim 4 , further comprising:
controlling an energy intensity of the patterned beam through changes of a reflection angle of each mirror.
6. A method according to claim 1 , wherein each laser spot is 0.1 mm.
7. A method according to claim 1 , wherein the pattern corresponds to a 10% to 100% of the layer of the article.
8. A method according to claim 1 , wherein the powder is a superalloy having a particle size of 10 to 60 μm.
9. An additive manufacturing system, comprising:
a build table configured to support an article to be manufactured from powder;
a laser source configured to generate a laser beam; and
a mirror array configured to pattern the laser beam and reflect the patterned laser beam onto the powder to melt the powder, wherein the pattern corresponds to a portion of a layer of the article, the patterned laser beam comprises a plurality of laser spots, groups of 9-25 mirrors are configured to provide each laser spot of the patterned laser beam, a power capacity of each mirror is 1 to 3 watts, and the groups of mirrors are configured to provide laser spots of 10 to 25 watts.
10. A system according to claim 9 , further comprising:
a powder spreader configured to spread a layer of powder over the layer of the article after solidification of the layer of the article.
11. A system according to claim 10 , wherein the build table is configured to move to adjust a position of the build table relative to the powder spreader.
12. A system according to claim 9 , further comprising:
an optical system configured to provide a desired distribution profile to the laser beam.
13. A system according to claim 12 , wherein the optical system is further configured to control an energy intensity of the patterned beam through changes of a reflection angle of each mirror.
14. A system according to claim 9 , wherein each laser spot is 0.1 mm.
15. A system according to claim 9 , wherein the pattern corresponds to a 10% to 100% of the layer of the article.
16. A system according to claim 9 , wherein the powder is a superalloy having a particle size of 10 to 60 μm.