SLS For Tooling Applications

Abstract

A system for sintering a tool within a laser sintering system includes a chamber enclosing a sinter material. The laser sintering system grows or sinters the tool from the sinter material in response to signals from a controller. The controller generates these signals as a function of a predetermined tool design. A heat sink is positioned within the chamber to cool features of the tool, thereby limiting warping of these features during sintering of the tool.

1 . A sintering system comprising: 
 a tool chamber enclosing a sinter material;    a first heat sink positioned within said tool chamber for cooling a predetermined feature of a tool thereby limiting warping of said predetermined feature during sintering of said tool;    a laser system sintering said sinter material as a function of controller signals; and    a controller generating said controller signals as a function of a predetermined tool design.    
   
   
       2 . The system of  claim 1  further comprising a plurality of heat sinks positioned within said tool chamber for cooling a plurality of predetermined features of said tool thereby limiting warping of said plurality of predetermined features during sintering of said tool.  
   
   
       3 . The system of  claim 1 , wherein said predetermined tool design comprises a buffer feature protecting said predetermined feature of said tool such that said buffer feature is primarily affected by heat generated during sintering in an area of said predetermined feature.  
   
   
       4 . The system of  claim 3 , wherein said buffer feature is removable such that damage is limited to said predetermined feature when said buffer feature is removed because of a predetermined weak connective link between said buffer feature and said predetermined feature.  
   
   
       5 . The system of  claim 1 , wherein said predetermined feature comprises at least one of a step and thickness variation, a gusset, a stiffener, an interface and coordination feature for making interfaces, a construction ball interface, a coordination hole, a trim of pocket and drill insert, a hole pattern, or a hole for interfacing hardware.  
   
   
       6 . The system of  claim 1 , wherein individual contoured details of said tool are sintered or manufactured during separate operations as said tool and later coupled to said tool.  
   
   
       7 . The system of  claim 1  further comprising a plurality of predetermined features comprising said predetermined feature, wherein all of said plurality of predetermined features are designed on a same side of said tool.  
   
   
       8 . A method for laser sintering a tool within a part chamber comprising: 
 predetermining positions of a plurality of tool features;    predetermining an orientation of the tool within the part chamber as a function of minimizing warping said tool features during sintering; and    laser sintering a sinter material to form the tool.    
   
   
       9 . The method of  claim 8  further comprising activating a heat sink within the part chamber for limiting warping of at least one of said plurality of tool features.  
   
   
       10 . The method of  claim 8  further comprising activating a plurality of heat sinks at predetermined times within the part chamber for limiting warping of said tool features.  
   
   
       11 . The method of  claim 8 , wherein predetermining said orientation of the tool within the part chamber as a function of minimize warping said tool features further comprises orienting the tool such that all of said tool features are on a same side of the tool.  
   
   
       12 . The method of  claim 8  further comprising predetermining a location of a buffer feature in a close proximity to at least one of said plurality of tool features.  
   
   
       13 . The method of  claim 12  further comprising removing said buffer feature from the tool following sintering of the tool.  
   
   
       14 . The method of  claim 8 , wherein predetermining positions of a plurality of tool features comprises predetermining positions for at least one of a step and thickness variation, a gusset, a stiffener, an interface and coordination feature for making interfaces, a construction ball interface, a coordination hole, a trim of pocket and drill insert, a hole pattern, or a hole for interfacing hardware.  
   
   
       15 . A sintering system comprising: 
 a part cylinder enclosing a sinter powder;    a first heat sink positioned within said tool chamber for cooling at least one of a plurality of predetermined features of a tool thereby limiting warping of said at least one of said plurality of predetermined features during sintering of said tool, wherein said plurality of predetermined features comprise at least one of a step and thickness variation, a gusset, a stiffener, an interface and coordination feature for making interfaces, a construction ball interface, a coordination hole, a trim of pocket and drill insert, a hole pattern, or a hole for interfacing hardware;    a laser system sintering said sinter material as a function of controller signals; and    a controller generating said controller signals as a function of a predetermined tool design, predetermined positions of said plurality of tool features, and a predetermined orientation of said tool within said part chamber as a function of minimize warping said tool features during sintering, wherein said predetermined tool design comprises a buffer feature protecting at least one of said plurality of predetermined features such that said buffer feature is primarily affected by heat generated during sintering in an area of said at least one of said plurality of predetermined features, wherein said plurality of predetermined features is designed on a same side of said tool.    
   
   
       16 . The system of  claim 15  further comprising a plurality of heat sinks positioned within said tool chamber for cooling a plurality of predetermined features of said tool thereby limiting warping of said plurality of predetermined features during sintering of said tool.  
   
   
       17 . The system of  claim 15 , wherein said buffer feature is removable such that damage is limited to said predetermined feature when said buffer feature is removed due to a weak connective link between said buffer feature and said predetermined feature.  
   
   
       18 . The system of  claim 15 , wherein individual contoured details of said tool are sintered or manufactured during separate operations as said tool and later coupled to said tool.  
   
   
       19 . A method for laser sintering a tool comprising: 
 predetermining a position for a first tool feature on a first section of the tool;    predetermining an orientation of said first section of the tool within the part chamber as a function of minimizing warping of said first tool feature during sintering;    activating a heat sink within a part chamber for limiting warping of said first tool feature;    laser sintering said first section of the tool within said part chamber;    predetermining a position for a second tool feature on a second section of the tool;    predetermining an orientation of said second section of the tool within said part chamber as a function of minimizing warping of said second tool feature during sintering;    laser sintering said second section of the tool; and    coupling said second section to said first section.    
   
   
       20 . The method of  claim 19  further comprising predetermining positions of a plurality of tool features on said first section of the tool.  
   
   
       21 . The method of  claim 20 , wherein predetermining said orientation of the tool within the part chamber as a function of minimize warping said tool features further comprises orienting the tool such that all of said tool features are on a same side of the tool.  
   
   
       22 . The method of  claim 19  further comprising predetermining positions of a plurality of tool features on said second section of the tool.  
   
   
       23 . The method of  claim 19  further comprising activating a plurality of heat sinks at predetermined times within said part chamber for limiting warping of a plurality of predetermined tool features on either said first section or said second section.  
   
   
       24 . The method of  claim 19  further comprising predetermining a location of a buffer feature in a close proximity to said first tool feature.  
   
   
       25 . The method of  claim 24  further comprising removing said buffer feature from the tool following sintering of the tool.  
   
   
       26 . The method of  claim 19 , wherein predetermining positions of said first tool feature further comprise predetermining a position for at least one of a step and thickness variation, a gusset, a stiffener, an interface and coordination feature for making interfaces, a construction ball interface, a coordination hole, a trim of pocket and drill insert, a hole pattern, or a hole for interfacing hardware.  
   
   
       27 . The method of  claim 19  further comprising activating a second heat sink within said part chamber for limiting warping of said second tool feature.  
   
   
       28 . A method for laser sintering a tool from a sinter material comprising: 
 sintering a first tool feature in a first tool section;    cooling said first tool feature during sintering of said first tool section;    sintering a second tool feature in a second tool section;    cooling said second tool feature during sintering of said second tool section; and    coupling said second section to said first section.    
   
   
       29 . The method of  claim 28  further comprising predetermining an orientation of said first section within a part chamber as a function of minimizing warping of said first tool feature during sintering.  
   
   
       30 . The method of  claim 28  further comprising predetermining an orientation of said second section within a part chamber as a function of minimizing warping of said second tool feature during sintering.  
   
   
       31 . The method of  claim 29  further comprising predetermining a location of a buffer feature in a close proximity to said first tool feature.  
   
   
       32 . The method of  claim 31  further comprising removing said buffer feature from the tool following sintering of the tool.  
   
   
       33 . The method of  claim 31  further comprising predetermining positions of a plurality of tool features on said first section of the tool.  
   
   
       34 . The method of  claim 33  further comprising orienting said first section such that all of said plurality of tool features are on one side of the tool.  
   
   
       35 . The method of  claim 28  further comprising sintering a contour detail; and coupling said contour detail to said first section.  
   
   
       36 . The method of  claim 35 , wherein coupling said contour detail further comprises coupling said contour detail to said first section through either a sintered bolt or a standard bolt or bolting system.  
   
   
       37 . The method of  claim 28  further comprising sintering a plurality of contour details; and coupling said plurality of contour details to both said first section and said second section.  
   
   
       38 . A method for sintering a tool comprising: 
 sintering a first plurality of predetermined tool features in a first tool section;    predetermining an orientation of said first tool section within a part chamber as a function of minimizing warping said first plurality of tool features during sintering;    cooling at least one of said first plurality of predetermined tool features during sintering of said first tool section;    sintering an interchangeable contour detail;    coupling said contour detail to said first tool section;    sintering a second plurality of predetermined tool features in a second tool section;    cooling said second tool feature during sintering of said second tool section;    coupling said second section to said first section.    
   
   
       39 . The method of  claim 38 , wherein coupling said contour detail further comprises coupling said contour detail to said first section through either a sintered bolt or a standard bolt or bolting system.  
   
   
       40 . The method of  claim 38  further comprising predetermining a location of a buffer feature for at least one of said first plurality of predetermined tool features; and removing said buffer feature from the tool following sintering of the tool.