Apparatuses, systems and methods for three-dimensional printing
First Claim
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1. A method for generating a three-dimensional object suspended in a powder bed, comprising:
- (a) providing the powder bed in an enclosure, wherein the powder bed comprises individual particles formed of a material selected from the group consisting of an elemental metal, metal alloy, ceramic, and an allotrope of elemental carbon;
(b) transforming at least a portion of the powder bed into a transformed material; and
(c) hardening the transformed material to form a hardened material as part of the three-dimensional object, which three-dimensional object comprises one or more layers of hardened material and is suspended in the powder bed during formation, wherein all layers of hardened material have a radius of curvature of at least about 5 centimeters up to substantially flat, and wherein the powder bed is devoid of a supporting scaffold substantially enclosing the three-dimensional object.
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Abstract
The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.
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Citations
22 Claims
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1. A method for generating a three-dimensional object suspended in a powder bed, comprising:
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(a) providing the powder bed in an enclosure, wherein the powder bed comprises individual particles formed of a material selected from the group consisting of an elemental metal, metal alloy, ceramic, and an allotrope of elemental carbon; (b) transforming at least a portion of the powder bed into a transformed material; and (c) hardening the transformed material to form a hardened material as part of the three-dimensional object, which three-dimensional object comprises one or more layers of hardened material and is suspended in the powder bed during formation, wherein all layers of hardened material have a radius of curvature of at least about 5 centimeters up to substantially flat, and wherein the powder bed is devoid of a supporting scaffold substantially enclosing the three-dimensional object. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A system for generating a three-dimensional object suspended in a powder bed, comprising:
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an enclosure that accommodates the powder bed, wherein the powder bed comprises individual particles formed of a material selected from the group consisting of an elemental metal, metal alloy, ceramic, and an allotrope of elemental carbon; an energy source that provides an energy beam to at least a portion of the powder bed; and a controller operatively coupled to the energy source and programmed to (i) receive instructions to generate at least a portion of the three-dimensional object and (ii) direct the energy beam along a predetermined path in accordance with the instructions to transform the at least a portion of the powder bed to a transformed material that hardens to form a hardened material as part of the three-dimensional object, which three-dimensional object comprises one or more layers of hardened material and is suspended in the powder bed during formation, wherein all layers of hardened material have a radius of curvature of at least about 5 centimeters up to substantially flat, and wherein upon formation of the hardened material, the powder bed is devoid of a supporting scaffold substantially enclosing the three-dimensional object. - View Dependent Claims (18, 19, 20, 21, 22)
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Specification