Processing Problems Associated with Gas Phase Solid Freeform Fabrication Using Pyrolytic Selective Area Laser Deposition

Concerns critical to selective area laser deposition are discussed. Variables affecting deposition rate, dimensional control, and surface uniformity are analyzed. Localized growth results in undesirable morphology, and contributing factors are cited. Catalytic powders increase nucleation rate and provide superior temperature profiles resulting in good surface uniformity. Specific process control devices are investigated.