Patent ID: 6429402
Filing Date: 2002-08-06
Classification: B22F,B23K,B29C,Y02P

Abstract:
A method of forming a wire from materials in particulate form, said method comprising:(a) defining the shape and dimensions of a wire; (b) creating control commands effective to form said wire by deposition of molten material along a deposition path in a single axis; (c) focusing a laser beam at a location within a deposition zone; (d) providing particulate material to said deposition zone; (e) forming a pool of molten material in said deposition zone by melting a portion of an article support and said particulate material by means of energy provided by said laser beam; (f) depositing molten material from said deposition zone on said article support at points along a first portion of said deposition path by moving said deposition zone along said deposition path, where said molten material solidifies after leaving said deposition zone, in order to form a portion of said wire which is adjacent to said article support; (g) forming a pool of molten material in said deposition zone by melting a portion of said partially formed wire and said particulate material by means of energy provided by said laser beam; (h) depositing molten material from said deposition zone at points along a second portion of said deposition path by moving said deposition zone along said deposition path, where said molten material solidifies after leaving said deposition zone, in order to continue formation of said wire; and (i) controlling flow of particulate material into said deposition zone, energy density of said laser beam, speed of withdrawal of said deposition zone from wire being formed, and focal position of said laser beam by means of said control commands as deposition takes place.