US 12,485,606 B1
System and method for improving mechanical properties of polymer powder bed fusion processes
Nathan Brad Crane, Lutz, FL (US); Justin Troy Nussbaum, Tampa, FL (US); Garrett Michael Craft, Wesley Chapel, FL (US); and Julie P. Harmon, Tampa, FL (US)
Assigned to University of South Florida, Tampa, FL (US)
Filed by University of South Florida, Tampa, FL (US)
Filed on Apr. 1, 2019, as Appl. No. 16/371,803.
Claims priority of provisional application 62/650,701, filed on Mar. 30, 2018.
Int. Cl. B29C 64/00 (2017.01); B22F 10/10 (2021.01); B28B 1/00 (2006.01); B29C 64/153 (2017.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); B33Y 80/00 (2015.01); B29C 64/264 (2017.01)
CPC B29C 64/153 (2017.08) [B22F 10/10 (2021.01); B28B 1/001 (2013.01); B33Y 10/00 (2014.12); B33Y 70/00 (2014.12); B33Y 80/00 (2014.12); B22F 2304/10 (2013.01); B29C 64/264 (2017.08)] 15 Claims
OG exemplary drawing
 
1. A sintering method comprising:
(a) providing a layer of powder material on a platform; wherein the powder material is not a metal and comprises a polymer;
(b) projecting an incident light from a source onto a surface area of the layer of powder material, wherein the incident light is projected for a sufficient time to densify the layer of powder material and form a layer of densified material, and wherein densifying the layer of powder material comprises melting the powder material, and wherein an area of the incident light projected on the surface of the layer of powder material and a thickness of the layer of powder material are in a ratio of at least 30:1, wherein the incident light is projected at a power level from 1 W/cm2 to 50 W/cm2;
(c) cooling the layer of densified material to below its recrystallization temperature to solidify the layer of densified material to form a layer of sintered material; and
(d) repeating steps (a) to (c) to form a sintered article in a layer-wise fashion,
wherein the article comprises greater than one layer of sintered material; and
wherein the powder material is premixed with a radiation absorber prior to step (a).