Method and apparatus for producing parts by selective sintering

[54] METHOD AND APPARATUS FOR PRODUCING PARTS BY SELECTIVE SINTERING

[75] Inventor: Carl R. Deckard, Austin, Tex.

[73] Assignee: Board of Regents, The University of Texas System, Austin, Tex.

[21] Appl. No.: 920,580

[22] FUed: Oct. 17,1986

[51] Int. a." B27N 3/00; B32B 31/00;

B23K 9/00; B29C 67/00

[52] U.S. a 156/62.2; 156/272.8;

219/121.66; 219/121.8; 219/121.85; 264/58;

264/113; 264/125

[58] Field of Search 219/121 LE, 121 LF,

219/121 LC, 121 LD, 121 LW, 121 LM; 419/5, 8; 427/53.1; 428/548; 156/630,643, 345, 272.8, 62.2; 264/56, 58-67, 113, 122, 125, 126,

127

[56] References Cited

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3,848,104 11/1974 Locke 219/121 LE

3,985,995 10/1976 Brandi et al 219/76

4,117,302 9/1978 Earle et al 219/121 LM

4,135,902 -1/1-979 Oehrle 219/121 LF

4,270,675 6/1981 Wicks et al 222/156

4,300,474 11/1981 Livsey 118/641

4,323,756 4/1982 Brown et al 219/121 LF

4,474,861 10/1984 Ecer 219/121.65 X

4,540,867 9/1985 Ackerman 219/121 LN

4,575,330 3/1986 Hall 425/174

4,752,352 6/1988 Feygin 428/548 X

FOREIGN PATENT DOCUMENTS

0209366 1/1987 European Pat. Off. .
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137951 10/1979 Fed. Rep. of Germany .
57-156959 3/1984 Japan .
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United Kingdom .

OTHER PUBLICATIONS

Takei et al., Journal of Applied Physics, "Rhenium Film Preparation By Laser Melting", May 1980, pp. 2903-2308.

"Sculpting Parts with Light", Machine Design (Mar. 6,

1986) pp. 102-106.

Chicago Enterprise, vol. I, No. II (May 1987).
Grain's Chicago Business (1987).
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Sample Cover Letter from Hydronetics, Inc.
Electronic Engineering Times, Issue 430 (Apr. 20,

1987) .

Primary Examiner—William A. Powell

Attorney, Agent, or Firm—Arnold, White & Durkee

1215184 12/1970

A method and apparatus for selectively sintering a layer of powder to produce a part comprising a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. The powder can comprise either plastic, metal, ceramic, or polymer substance. In the preferred embodiment, the aim of the laser is directed in a continuous raster scan and the laser turned on when the beam is aimed with the boundaries of the particular cross-section being formed.

31 Claims, 4 Drawing Sheets