Abstract: A method of fabricating a fully dense, three dimensional object by direct laser sintering is disclosed. In a chamber with a partial pressure atmosphere, a beam of directed energy melts metallic powder in order to form a solid layer cross section. Another layer of powder is deposited and melted, along with a portion of the previous layer. The energy beam typically is in the form of a laser, scanning along a path resembling a parametric curve or another, arbitrary piecewise parametric curve. In another embodiment, the previous layer is not remelted, thus creating an oxide film that acts as a clean stop to prevent unwanted downward growth.

Abstract: A selective laser sintering technique and system are provided for producing a heterogeneous product. The selective laser sintering technique and system is generally comprised of generating a computer model of the product and processing the model to obtain numerous cross-sectional representations of the model. The cross-sectional representations are manufactured layer by layer to create the product. Specifically, numerous different powders having a variety of properties are placed within nozzles positioned above a deposition bed using a hopper. Using the computer model as a guide, the different powders are placed at different positions on the deposition bed to form each layer of the device. The deposited powders are consolidated, micromachined, and milled using one or more lasers to create the product.

Abstract: The present invention relates to a method an apparatus for fabricating a component by a direct laser process. One form of the present invention contemplates a gas turbine engine blade having an abrasive tip formed directly thereon.

Abstract: A method of fabricating a fully dense, three dimensional object by direct laser sintering is disclosed. In a chamber with a partial pressure atmosphere, a beam of directed energy melts metallic powder in order to form a solid layer cross section. Another layer of powder is deposited and melted, along with a portion of the previous layer. The energy beam typically is in the form of a laser, scanning along a path resembling a parametric curve or another, arbitrary piecewise parametric curve. In another embodiment, the previous layer is not remelted, thus creating an oxide film that acts as a clean stop to prevent unwanted downward growth.

Abstract: The present invention relates to a method an apparatus for fabricating a component by a direct laser process. One form of the present invention contemplates a gas turbine engine blade having an abrasive tip formed directly thereon.