Tailored particles for power-based additive manufacturing

Abstract

The present disclosure relates to a plurality of powder particles configured to be joined in an additive manufacturing process to form a part, and wherein each one of the powder particles comprises a three dimensional, non-spherical shape. The non-spherical shape of each one of the plurality of powder particles may be at least one of identical in three dimensional shape, or at least partially complementary in three dimensional shape, to each other. The plurality of powder particles may further be of dimensions enabling fitting individual ones of the plurality of particles in abutting relationship with one another with substantially no voids between them.

What is claimed is: 
     
         1 . A plurality of powder particles configured to be joined in an additive manufacturing process to form a part, each one of said powder particles comprising:
 a determined three dimensional, non-spherical shape;   the non-spherical shape of each one of the plurality of powder particles being at least one of identical in three dimensional shape or at least partially complementary in three dimensional shape to each other; and   the plurality of powder particles further being of dimensions enabling fitting individual ones of the plurality of particles in abutting relationship with one another with substantially no voids between them.   
     
     
         2 . The powder particles of  claim 1 , wherein the powder particles all have a uniform three dimensional shape. 
     
     
         3 . The powder particles of  claim 1 , wherein the powder particles all have uniform dimensions. 
     
     
         4 . The powder particles of  claim 1 , wherein the powder particles all have uniform dimensions and a uniform three dimensional shape. 
     
     
         5 . The powder particles of  claim 1 , wherein the plurality of powder particles have differing but at least partially complementary shapes. 
     
     
         6 . The powder particles of  claim 5 , wherein the plurality of powder particles include first particles and second particles having differing but at least partially complementary shapes, and wherein the first and second powder particles further include dimensions which enable them to be fit together in abutting relationship with substantially no voids between them. 
     
     
         7 . The powder particles of  claim 6 , wherein the first powder particles comprise an octahedral shape. 
     
     
         8 . The powder particles of  claim 7 , wherein the second powder particles comprise a cuoboctahedral shape. 
     
     
         9 . The powder particles of  claim 1 , wherein the powder particles each comprise a non-convex stellation of a rhombic dodecahedron. 
     
     
         10 . The powder particles of  claim 9 , wherein the powder particles are all of the same dimensions. 
     
     
         11 . The powder particles of  claim 1 , wherein the powder particles all comprise a cubic square shape. 
     
     
         12 . The powder particles of  claim 1 , wherein the powder particles comprise first and second groups of powder particles;
 the first group of powder particles having a first magnetic dipole arrangement; and   the second group of powder particles having a second magnetic dipole arrangement different from the first magnetic dipole arrangement.   
     
     
         13 . The powder particles of  claim 12 , wherein the powder particles of the first group are attracted to one another, but are repelled from the powder particles of the second group. 
     
     
         14 . The powder particles of  claim 13 , wherein the powder particles of the first and second groups all have the same shape. 
     
     
         15 . The powder particles of  claim 13 , wherein the powder particles of the first and second groups all have the same dimensions. 
     
     
         16 . The powder particles of  claim 1 , wherein at least one of a porosity or a material of a first subplurality of the powder particles differs from at least one of a porosity or material of a second subplurality of the powder particles. 
     
     
         17 . A plurality of powder particles configured to be joined in an additive manufacturing process to form a three dimensional part, each one of said powder particles comprising:
 first and second three dimensional, non-spherical shapes which differ from one another;   the first and second non-spherical shapes being at least partially complementary in three dimensional shape to each other; and   dimensions of the first and second non-spherical shapes further enabling fitting individual ones of the plurality of particles in a layered configuration, and in abutting relationship with one another, with substantially no voids between them.   
     
     
         18 . The powder particles of  claim 17 , wherein at least one of a porosity or a material of a first subplurality of the powder particles differs from at least one of a porosity or material of a second subplurality of the powder particles. 
     
     
         19 . The powder particles of  claim 17 , wherein the powder particles comprise first and second groups of powder particles;
 the first group of powder particles having a first magnetic dipole arrangement; and   the second group of powder particles having a second magnetic dipole arrangement different from the first magnetic dipole arrangement.   
     
     
         20 . A method of constructing a three dimensional part using a plurality of powder particles configured to be joined in an additive manufacturing process, the method comprising:
 forming a plurality of powder particles each having a determined three dimensional, non-spherical shape;   the non-spherical shape of each one of the plurality of powder particles being at least one of identical in three dimensional shape or at least partially complementary in three dimensional shape to each other;   the plurality of powder particles further being formed with dimensions enabling fitting individual ones of the plurality of particles in abutting relationship with one another with substantially no voids between them;   arranging the powder particles on a support structure in an ordered arrangement having substantially no voids between the particles; and   joining the particles to form at least a layer of a finished 3D part.