Abstract: A dispensing system for an additive manufacturing includes a powder source that contains powder to form an object, and an array of nozzles positioned at a base of the powder source over a top surface of a platen where the object is to be formed. The powder flows from the powder source through the nozzles to the top surface. A respective powder wheel in each nozzle controls a flow rate of the powder. Each wheel has multiple troughs on surface of the wheel. When a motor rotates the wheel, the troughs transport the powder through the nozzle. The rotation speed of the wheel controls the flow rate. For solid parts of the object, the wheel rotates and allows the powder to be deposited on the top surface. For empty parts of the object, the wheel remains stationary to prevent the powder from flowing to the surface.

Abstract: An additive manufacturing apparatus includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, and an energy delivery assembly. The energy delivery assembly includes a light source to emit one or more light beams, a first reflective member having a plurality of reflective facets, and at least one second reflective member. The first reflective member is rotatable such that sequential facets sweep the light beam sequentially along a path on the uppermost layer. The at least one second reflective member is movable such that the at least one second reflective surface is repositionable to receive at least one of the at least one light beam and redirect the at least one of at least one light beam along a two-dimensional path on the uppermost layer.

Abstract: An additive manufacturing apparatus includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, an energy delivery system, and an actuator. The energy delivery system includes a light source to emit a light beam, and a reflective member having a plurality of reflective facets, the reflective member positionable in a path of the light beam to receive the light beam and redirect the light beam toward the top surface of the platform to deliver energy to an uppermost layer of the layers of feed material to fuse the feed material. The reflective member is rotatable such that sequential facets sweep the light beam sequentially along a linear path on the uppermost layer. The actuator is configured to adjust an angle of the linear path relative to the platform.

Abstract: An additive manufacturing apparatus includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, and an energy delivery system. The energy deliver system includes a light source to emit a light beam, and a reflective member having a plurality of reflective facets. The reflective member is positioned in a path of the light beam to receive the light beam and redirect the light beam toward the top surface of the platform to deliver energy to an uppermost layer of the layers of feed material to fuse the feed material. The reflective member is rotatable such that sequential facets sweep the light beam sequentially along a path on the uppermost layer.

Abstract: An additive manufacturing system includes a platen to support an object being manufactured, a dispenser to deliver a plurality of successive layers of a powder over the platen, and energy source configured to fuse at least a portion of the powder. The dispenser is configured to deliver the powder in a linear region that extends along a first axis. The dispenser and actuator are supported by a support structure, and the actuator is coupled to the support structure to move the support structure along a second axis perpendicular to the first axis such that the dispenser and energy source move as a single unit with the support structure and the linear region sweeps along the second axis to deposit the powder along a swath over the platen to form a layer of powder.

Abstract: An additive manufacturing system includes a platen, a dispenser apparatus positioned above the platen to dispense a layer of powder over the platen, and an energy source to selectively fuse the layer of powder. The dispenser apparatus includes a support structure, a dispenser secured to the support structure and including a reservoir to hold the powder and one or more openings configured to deliver powder from the reservoir in a linear region that extends along a first axis, a spreader extending along the first axis and secured to the support structure and positioned to spread powder already delivered on the platen by the dispenser, and a drive system to move the support structure along a second axis perpendicular to the first axis such that the dispenser and blade move together to sweep the linear region along the second axis to deposit and level the powder.

Abstract: An apparatus includes a platen and a dispensing system overlying the platen. The dispensing system includes a powder source. The dispensing system further includes a powder conveyor extending over the top surface of the platen, rings arranged coaxially along a longitudinal axis of the powder conveyor, and a cap plate extending along a length of the tube. The powder conveyor is configured to receive powder from the powder source. The powder conveyor is configured to move the powder. The rings form a tube surrounding the powder conveyor to contain the powder. Each concentric ring includes a ring opening. Each ring is configured to be independently rotatable. The cap plate includes a cap plate opening. The powder is dispensed from the tube through the ring opening and the cap plate opening when the ring opening and the cap plate opening are aligned.

Abstract: A module for an additive manufacturing system includes a frame configured to be removably mounted on a movable support, a dispenser configured to deliver a layer of particles on a platen that is separate from the frame or an underlying layer on the platen, a heat source configured to heat the layer of particles to a temperature below a temperature at which the particles fuse, and an energy source configured to fuse the particles. The dispenser, heat source and energy source are positioned on the frame in order along a first axis, and the dispenser, heat source and energy source are fixed to the frame such that the frame, dispenser, heat source and energy source can be mounted and dismounted as a single unit from the support.

Abstract: An additive manufacturing system includes a platen having a top surface to support an object being manufactured, a support that is movable along a vertical axis, an actuator to move the support along the vertical axis, a dispenser to deliver a plurality of successive layers of feed material over the platen, an energy source configured to fuse at least a portion of the feed material, and a controller. The dispenser and energy source are mounted on the support over the platen such that motion of the support along the vertical axis moves the dispenser and energy source together toward or away from the top surface of the platen. The controller is coupled to the actuator, dispenser and energy source and configured to cause the actuator to move the support to lift the dispenser and actuator away from the top surface after each of the plurality of successive layers is delivered.

Abstract: An apparatus for forming an object includes a platform to support the object. The platform includes a first support plate including first holes and a second support plate arranged below the first support plate and including second holes. The second support plate is movable relative to the first support plate between an aligned configuration and a misaligned configuration. The apparatus further includes a dispensing system overlying the support plate to dispense a powder over the top surface of the first support plate and an energy source to apply energy to the powder dispensed on the top surface of the first support plate to form a fused portion of the powder. In the aligned configuration, the first holes are aligned with the second holes such that unfused powder can pass through the first holes into the second holes. In the misaligned configuration, the first holes are misaligned with the second holes.

Abstract: An apparatus for forming an object includes a platform and a dispensing system overlying the platform to dispense successive layers of powder. The successive layers include support layers and object layers on the support layers. The apparatus further includes an energy source to fuse the powder. A controller is configured to cause the energy source to fuse a support region of each of the support layers to form a part support base. The controller is further configured to cause the energy source to fuse an enclosure region of each of the object layers to form an enclosure dividing each of the object layers into an inner region and outer region. The controller is also configured to cause the energy source to fuse an object portion of the inner region of each of the object layers. A parallel projection of the object defines a part area contained within the inner region.

Abstract: An additive manufacturing system includes a platen having a top surface to support an object being manufactured, a support structure, an actuator coupled to at least one of the platen or the support structure to create relative motion there between along a first axis parallel to the top surface, a plurality of printheads mounted on the support structure, and an energy source. Each printhead includes a dispenser to deliver a plurality of successive layers of feed material over the platen. The printheads are spaced along a second axis perpendicular to the first axis such that during motion along the first axis the plurality of printheads dispense feed material in a plurality of parallel swaths along the first axis. The energy source is configured to fuse at least a portion of the feed material.

Abstract: A method of joining two silicon members, the adhesive used for the method, and the joined product, especially a silicon tower for supporting multiple silicon wafers. A flowable adhesive is prepared comprising silicon particles of size less than 100 ?m and preferably less than 100 nm and a silica bridging agent, such as a spin-on glass. Nano-silicon crystallites of about 20 nm size maybe formed by CVD. Larger particles maybe milled from virgin polysilicon. If necessary, a retardant such as a heavy, preferably water-insoluble alcohol such as terpineol is added to slow setting of the adhesive at room temperature. The mixture is applied to the joining areas. The silicon parts are assembled and annealed at a temperature sufficient to link the silica, preferably at 900° C. to 1100° C. for nano-silicon but higher for milled silicon.

Abstract: A hybrid nozzle for use in a plasma spray gun, especially for plasma spraying silicon to form semiconductor devices such as solar cell. The outlet of the gun includes a two-piece annular electrode against which the plasma is ignited and through which the plasma plume exits the gun together with entrained silicon. In one embodiment, the upstream part is composed of graphite to allow ignition of the plasma and the downstream part is composed of pure silicon. In another aspect, the silicon feedstock is injected into the plasma plume through ports formed through the silicon part.

Abstract: A linear process tool comprising at least two deposition modules each comprising one or more plasma spray guns operable to move in a direction approximately orthogonal to the direction of a substrate carrier is configured to deposit at least a first and second layer, in direct contact with each other, wherein a first layer is of first composition and the second layer is of second composition different than the first composition.

Abstract: Doped silicon particles, including powder suitable for plasma spraying semiconductor devices, is formed by liquid doping applied to larger particles, which are then milled to a smaller size. Doped or undoped silicon may be milled by a roller mill including silicon rollers and advantageously having feed and collection systems formed of silicon and operated in a nitrogen ambient. A two-stage system includes sieving the rolled product for further size reduction in a jet mill.

Abstract: A hybrid nozzle for use in a plasma spray gun, especially for plasma spraying silicon to form semiconductor devices such as solar cell. The outlet of the gun includes a two-piece annular electrode against which the plasma is ignited and through which the plasma plume exits the gun together with entrained silicon. In one embodiment, the upstream part is composed of graphite to allow ignition of the plasma and the downstream part is composed of pure silicon. In another aspect, the silicon feedstock is injected into the plasma plume through ports formed through the silicon part.

Abstract: A bottle adaptor to which one or more bottles of one or more standard threaded-tops may be screwed and sealed to allow sipping of the fluid in the bottles through a flexible drinking tube. The adaptor and bottles may be carried in a backpack. One or two bottle receivers include plural standard threads spaced along an axis and a socket for a straw to project to the bottom of the bottle. A fluid passageway from the drinking tube extends to the straw sockets. Each bottle receiver includes a selectively openable pressure relief from the ambient to the space adjacent the bottle threads. A separate tube coupler having barbs for the drinking tube may be inserted into and locked to the adaptor. For a two-bottle adaptor, a three-way valve adjacent the barb or other tube connection may select either bottle or the shut condition.

Abstract: A method of joining two silicon members, the adhesive used for the method, and the joined product, especially a silicon tower for supporting multiple silicon wafers. A flowable adhesive is prepared comprising silicon particles of size less than 100 ?m and preferably less than 100 nm and a silica bridging agent, such as a spin-on glass. Nano-silicon crystallites of about 20 nm size maybe formed by CVD. Larger particles maybe milled from virgin polysilicon. If necessary, a retardant such as a heavy, preferably water-insoluble alcohol such as terpineol is added to slow setting of the adhesive at room temperature. The mixture is applied to the joining areas. The silicon parts are assembled and annealed at a temperature sufficient to link the silica, preferably at 900° C. to 1100° C. for nano-silicon but higher for milled silicon.

Abstract: A method of joining two silicon members, the adhesive used for the method, and the joined product, especially a silicon tower for supporting multiple silicon wafers. A flowable adhesive is prepared comprising silicon particles of size less than 100 ?m and preferably less than 100 nm and a silica bridging agent, such as a spin-on glass. Nano-silicon crystallites of about 20 nm size may be formed by CVD. Larger particles may be milled from virgin polysilicon. If necessary, a retardant such as a heavy, preferably water-insoluble alcohol such as terpineol is added to slow setting of the adhesive at room temperature. The mixture is applied to the joining areas. The silicon parts are assembled and annealed at a temperature sufficient to link the silica, preferably at 900° C. to 1100° C. for nano-silicon but higher for milled silicon.