Precision particle delivery via laser for 3D printing

[taylaron]

Greetings PFers,

I was thinking about methods of delivering mediums used in 3D printing process, specifically 'selective laser sintering'. Currently SLS uses layers of fine metal powder which are fused together, layer by layer. A new coating of powder is applied every layer. Afterwards, the un-fused powder is then blown off.

I began to think about Bernoulli's principle and how it might be utilized. Similar to how a ping-pong ball floats in a stream of air (http://www.californiasciencecenter.org/FunLab/DoItYourself/FloatingInAir/FloatingInAir.php )
What if two lasers of different intensity are used instead? In this situation, there would be a low intensity laser with a larger diameter, and a small diameter and high intensity laser coaxial with the first laser. There would be a difference in air temperature and pressure caused by the photon's interaction with air particles. Therefore, the higher intensity outer beam would be a lower pressure & temperature than the inner beam, mimicking Bernoulli principle.

Once the beam has been activated, by one means or another, a stream of powder would be injected into the smaller beam, which would be simultaneously propelled by the laser and confined to the laser's path. Once the particles traverse the beam, they fuse onto the part being printed. This would result in a very low mess and conserve material. There would be very little post-processing.

Despite the engineering challenges, is the concept physically sound or utterly impractical?
If it is sound, wouldn't it work without the outer laser since the ambient temperature should be a higher pressure and lower temperature than the air exposed to the laser?

Regards,
-Tay

 

[eljose79]

zron



Dear Tayzron,

Thank you for sharing your idea about utilizing Bernoulli's principle in the selective laser sintering process. Your concept is interesting and shows a creative approach to improving the efficiency and reducing the mess in 3D printing.

However, there are a few things to consider before determining the feasibility of this idea. First, the use of multiple lasers in the process can add complexity and cost to the system. It may also require precise alignment and control of the lasers, which could be challenging.

Secondly, the temperature and pressure differences caused by the lasers may not be significant enough to have a noticeable effect on the powder stream. Any changes in temperature and pressure would also depend on the properties of the powder being used.

Moreover, the use of lasers in this manner could potentially cause overheating and melting of the powder, leading to poor quality prints. This could also result in a higher energy consumption, which goes against the goal of reducing material waste.

Overall, while the concept is intriguing, it may not be practical for implementation in the current selective laser sintering process. Further research and experimentation would be needed to fully assess the potential benefits and drawbacks of this approach.

Thank you for bringing this idea to our attention. It is through open discussions and sharing of ideas that we can continue to improve and innovate in the field of 3D printing.