Method of temperature controlled additive manufacturing using lamps

Abstract

An additive manufacturing system includes a platen having a top surface to support an object being manufactured, a dispenser to deliver a plurality of successive layers of precursor material over the platen, a plurality of lamps disposed below the top surface of the platen to heat the platen, and an energy source to fuse at least some of the outermost layer of precursor material.

What is claimed is: 
     
         1 . A method of additive manufacturing, comprising:
 dispensing a plurality of successive layers of precursor material over a support;   heating the support using a plurality of lamps disposed below the support; and   applying energy to an outermost layer from an energy source positioned above the support to fuse at least a portion of the outermost layer.   
     
     
         2 . The method of  claim 1 , comprising independently controlling power applied to at least some of the plurality of lamps. 
     
     
         3 . The method of  claim 2 , wherein the plurality of lamps are arranged in a plurality of radial zones, and comprising independently controlling power applied to each radial zone. 
     
     
         4 . The method of  claim 3 , comprising isolating each radial zone with a Faraday cage. 
     
     
         5 . The method of  claim 2 , comprising adjusting heat applied by different lamps of the plurality of lamps to increase uniformity of a base temperature across a layer of the feed material. 
     
     
         6 . The method of  claim 1 , comprising isolating the plurality of lamps from a region above the support with a Faraday cage. 
     
     
         7 . The method of  claim 6 , wherein heating the support comprises directing light through a conductive mesh of the Faraday cage. 
     
     
         8 . The method of  claim 1 , comprising lowering the platen by a distance substantially equal to the thickness of a layer of the plurality of successive layers. 
     
     
         9 . The method of  claim 1 , wherein applying energy to the outermost layer comprises directing a laser beam onto the outermost layer. 
     
     
         10 . The method of  claim 1 , comprising generating a plasma in a region above the support. 
     
     
         11 . The method of  claim 10 , wherein generating the plasma comprises directing RF power comprising apply RF power to a conductive plate in the support. 
     
     
         12 . The method of  claim 11 , wherein applying RF power comprises carrying power through a piston rod to the conductive plate. 
     
     
         13 . The method of  claim 11 , comprising supporting the plurality of successive layers of precursor material on a dielectric coating covering a top surface of the conductive plate. 
     
     
         14 . The method of  claim 11 , comprising separating the plurality of lamps from the conductive plate using a dielectric plate. 
     
     
         15 . The method of  claim 1 , wherein dispensing, heating and applying energy are performed on the plurality of successive layers in a vacuum environment. 
     
     
         16 . The method of  claim 1 , wherein the precursor material comprises a metal powder.