Laser pulse shaping for additive manufacturing

Patent · Tue Oct 31 04:00:00 EDT 2023

OSTI ID:2293788

DeMuth, James A.; Bayramian, Andrew J.; Duoss, Eric B.; Kuntz, Joshua D.; Spadaccini, Christopher

The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components. The second beam component has a higher power level and a shorter duration than the first beam component. A mask creates a 2D optical pattern in which only select portions of the second beam components can irradiate the powder particles. The first beam component heats the powder particles close to a melting point, where the particles experience surface tension forces relative to the interface layer. While the particles are heated, the second beam component further heats the particles and also melts the interface layer before the surface tension forces can act on and distort the particles, enabling the particles and the interface layer are able to bond together.

• Research Organization: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
• Sponsoring Organization: USDOE
• DOE Contract Number: AC52-07NA27344
• Assignee: Lawrence Livermore National Security, LLC (Livermore, CA)
• Patent Number(s): 11,801,635
• Application Number: 17/984,786
• OSTI ID: 2293788
• Country of Publication: United States
• Language: English