Abstract: An energy beam driven rapid fabrication system, in which an energy beam strikes a growth surface to form a molten puddle thereon. Feed powder is then injected into the molten puddle from a converging flow of feed powder. A portion of the feed powder becomes incorporated into the molten puddle, forcing some of the puddle contents to freeze on the growth surface, thereby adding an additional layer of material. By scanning the energy beam and the converging flow of feed powder across the growth surface, complex three-dimensional shapes can be formed, ready or nearly ready for use. Nearly any class of material can be fabricated using this system.

Abstract: An energy beam driven rapid fabrication system, in which an energy beam strikes a growth surface to form a molten puddle thereon. Feed powder is then injected into the molten puddle from a converging flow of feed powder. A portion of the feed powder becomes incorporated into the molten puddle, forcing some of the puddle contents to freeze on the growth surface, thereby adding an additional layer of material. By scanning the energy beam and the converging flow of feed powder across the growth surface, complex three-dimensional shapes can be formed, ready or nearly ready for use. Nearly any class of material can be fabricated using this invention.

Abstract: A method and system are provided for producing complex, three-dimensional, net shape objects from a variety of powdered materials. The system includes unique components to ensure a uniform and continuous flow of powdered materials as well as to focus and locate the flow of powdered materials with respect to a laser beam which results in the melting of the powdered material. The system also includes a controller so that the flow of molten powdered materials can map out and form complex, three-dimensional, net-shape objects by layering the molten powdered material. Advantageously, such complex, three-dimensional net-shape objects can be produced having material densities varying from 90% of theoretical to fully dense, as well as a variety of controlled physical properties. Additionally, such complex, three-dimensional objects can be produced from two or more different materials so that the composition of the object can be transitioned from one material to another.