Solid freeform fabrication of structurally engineered multifunctional devices

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. Using this selective laser sintering technique a wide variety of heterogenous products may be produced, such as the following: 1) bio-implants, 2) small scale energy production, storage and conversion devices, 3) devices that exploit anomalous material behavior, and 4) nanocomposites.