	US 12,011,873 B2
	Additive manufacturing system for object creation from powder using a high flux laser for two-dimensional printing
Ning Duanmu, Nashua, NH (US); James A. DeMuth, Woburn, MA (US); Andrew J. Bayramian, Marblehead, MA (US); Yiyu Shen, Tewksbury, MA (US); and Drew W. Kissinger, Carlisle, MA (US)
Assigned to Seurat Technologies, Inc., Wilmington, MA (US)
Filed by Seurat Technologies, Inc., Mountain View, CA (US)
Filed on Dec. 12, 2019, as Appl. No. 16/712,355.
Claims priority of provisional application 62/779,978, filed on Dec. 14, 2018.
Prior Publication US 2020/0189038 A1, Jun. 18, 2020
Int. Cl. B29C 64/153 (2017.01); B22F 10/28 (2021.01); B22F 10/31 (2021.01); B22F 10/32 (2021.01); B22F 12/41 (2021.01); B22F 12/45 (2021.01); B23K 26/12 (2014.01); B23K 26/14 (2014.01); B23K 26/342 (2014.01); B29C 64/364 (2017.01); B29C 64/371 (2017.01); B33Y 10/00 (2015.01); B33Y 40/00 (2020.01); B22F 10/77 (2021.01); B22F 12/90 (2021.01)

CPC B29C 64/153 (2017.08) [B22F 10/28 (2021.01); B22F 10/31 (2021.01); B22F 10/32 (2021.01); B22F 12/41 (2021.01); B22F 12/45 (2021.01); B23K 26/125 (2013.01); B23K 26/128 (2013.01); B23K 26/1464 (2013.01); B23K 26/342 (2015.10); B29C 64/364 (2017.08); B29C 64/371 (2017.08); B33Y 10/00 (2014.12); B33Y 40/00 (2014.12); B22F 10/77 (2021.01); B22F 12/90 (2021.01)]

10 Claims

1. A method of additive manufacture, the method comprising:

providing an enclosure surrounding a powder bed and having an atmosphere including a helium gas;

directing a laser beam having a flux greater than 0.1 megawatts/square centimeter at a defined two dimensional region of the powder bed; and

melting and fusing powder within the defined two dimensional region of the powder bed, with less than 50% of a mass of powder particles being displaced in another defined two dimensional region sharing at least one of an edge and a corner with the defined two dimensional region of the powder bed where the powder melting and fusing occur,

wherein the atmosphere further comprises an inert sulfur hexafluoride gas (SF₆) that displaces other gases evolved from the powder during heating of the powder and at least one of i-C₄H₁₀, cic-2, C₄H₇, 1,3-C₄H₆, 1,2-C₄H₆, C₅H₁₂, i-C₅H₁₂, C₂H₃Cl, C₈H₁₈, C₁₀H₂₂, C₁₁H₂₄, C₁₂H₂₆, C₁₃H₂₈, C₁₄H₃₀, C₁₅H₃₂, C₁₆H₃₄, C₆H₆, C₆H₅—CH₃, C₈H₁₀, C₂H₅OH, CH₃OH, and iC₄H₈.