Method and apparatus for producing parts by selective sintering

TLDR: In this article, 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.

Abstract: A method and apparatus (10) for selectively sintering a layer of powder to produce a part comprising a plurality of sintered layers. The apparatus includes a computer (40) controlling a laser (12) 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 may consist of a 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 within the boundaries of the particular cross-section being formed. Preferably, the powder dispensing mechanism includes a drum which is moved horizontally across the target area and counter-rotated to smooth and distribute the powder in an even layer across the target area. A downdraft system provides controlled temperature air flow through the target area to moderate powder temperature during sintering.