Additive manufacturing with sealed pores

1. A method for additively manufacturing a three-dimensional structure, the method comprising:

depositing a plurality of stacked layers devoid of metal foaming agents; and

for at least one layer of the plurality of stacked layers, forming sealed pores within the layer by applying pulsed energy to the layer, and using respective pulses of the pulsed energy to create a fully sealed space within the three-dimensional structure and having an inner surface defined by material of the three-dimensional structure, therein creating the three-dimensional structure with pores sealed within an outer suface.

2. The method of claim 1 , wherein forming the pores within the layer by applying pulsed energy includes:

applying an energy pulse via an upper surface of the layer and using the energy pulse to form an open cavity in the layer and extending from the upper surface to a depth within the layer; and

terminating the energy pulse and causing an upper portion of the cavity to collapse, therein forming a sealed space at the depth within the layer.

3. The method of claim 1 , wherein forming the pores within the layer by applying pulsed energy includes scanning a laser via an upper surface of the layer, by:

forming a first open cavity in the layer by applying a first laser pulse to a first portion of the upper surface, the first open cavity extending from the upper surface to a depth within the layer;

collapsing an upper portion of the first open cavity and therein forming the sealed space at the depth within the layer, by terminating the first laser pulse; and

after the laser is scanned past the first portion of the upper surface, forming a second open cavity in the layer by applying a second laser pulse via a second portion of the upper surface, the second open cavity extending from the upper surface to a depth within the layer, and collapsing an upper portion of the second open cavity and therein forming another sealed space at the depth within the layer, by terminating the first laser pulse.

4. The method of claim 1 , wherein applying the pulsed energy includes applying energy pulses having a beam size, and controlling the size of each pore based on at least one characteristic selected from the group of: the size of the beam, laser frequency, and laser duty cycle.

5. The method of claim 1 , wherein applying the pulsed energy includes controlling the size of each pore by controlling at least one characteristic selected from the group of: an amount of the pulsed energy applied, a frequency of the pulsed energy, and a duty cycle of the pulsed energy.

6. The method of claim 1 , wherein forming the pores includes forming pores at a defined density by applying the pulsed energy to respective locations of the layer corresponding to the defined density.

7. The method of claim 1 , wherein forming the pores includes forming the pores in a pattern and therein tuning the properties of the three-dimensional structure via the pores.

8. The method of claim 1 , wherein forming the pores includes forming the pores in a pattern and therein reinforcing the three-dimensional structure with added function provided via the pores.

9. The method of claim 1 , wherein applying the pulsed energy includes scanning a pulsed energy source across the layer, and wherein forming the pores includes controlling distance between the pores by setting a time between which respective pulses are applied.

10. The method of claim 1 , wherein forming the pores includes adjusting the shape of the pores by adjusting temporal and spatial profiles of the pulsed energy.

11. The method of claim 1 , wherein applying the pulsed energy includes applying pulsed laser energy.

12. The method of claim 1 , wherein applying the pulsed energy includes applying pulsed electron beam energy.

13. The method of claim 1 , wherein applying the pulsed energy includes:

applying a first pulse to create a cavity; and

applying a second pulse to create a melt pool that covers an upper portion of the cavity to form a pore.

14. The method of claim 1 , wherein applying the pulsed energy includes:

applying a first pulse to create a first cavity; and

applying a second pulse to create a melt pool that covers an upper portion of the first cavity to form a first pore, and to form a second cavity for a second pore.

15. The method of claim 1 , wherein forming the pores includes sealing the pores with the material from the layer that is melted via the pulsed energy and forming the pores without utilizing a metal foaming agent, therein mitigating entry of contamination into the pores.

16. The method of claim 1 , wherein depositing the plurality of stacked layers includes:

depositing a powder bed of material that is devoid of metal foaming agents over an underlying layer; and

melting the powder bed of material via the applied pulsed energy while using the applied pulsed energy to form a pore in the underlying layer.

17. The method of claim 1 , wherein depositing the plurality of stacked layers and forming the pores includes using the applied pulsed energy to simultaneously melt deposited material and form a pore underlying the deposited material being melted.

18. The method of claim 1 , wherein depositing the plurality of stacked layers includes depositing a powder bed of material over an underlying layer and melting the powder bed of material by applying initial pulsed energy, prior to applying the pulsed energy to create pores in the underlying layer.

19. An apparatus comprising:

a plurality of stacked layers devoid of metal foaming agents; and

a plurality of pores in at least one of the stacked layers, each pore having an inner surface defined and fully sealed by material of a layer in which it is formed, each pore being spaced from adjacent ones of the pores by a defined gradient and being sealed within an outer surface of the apparatus.

20. The apparatus of claim 19 , wherein each pore has an upper portion of the inner surface characterized by a re-melted portion of the material of the layer that seals a previously melted and solidified portion of the inner surface.