Systems for three-dimensional printing
First Claim
Patent Images
1. A system for forming a three-dimensional object, comprising:
- a powder dispenser that dispenses a powder material to form at least a portion of a powder bed comprising a first exposed surface, which powder bed is adjacent to the powder dispenser that is laterally translatable with respect to the powder bed;
a powder removal member that is disposed above the powder bed and is laterally translatable with respect to the powder bed, wherein the powder removal member planarizes the first exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a second exposed surface that is planar, wherein the powder removal member comprises an opening for removing powder material from the powder bed;
an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object;
a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and
a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface.
6 Assignments
0 Petitions
Accused Products
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.
-
Citations
29 Claims
-
1. A system for forming a three-dimensional object, comprising:
-
a powder dispenser that dispenses a powder material to form at least a portion of a powder bed comprising a first exposed surface, which powder bed is adjacent to the powder dispenser that is laterally translatable with respect to the powder bed; a powder removal member that is disposed above the powder bed and is laterally translatable with respect to the powder bed, wherein the powder removal member planarizes the first exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a second exposed surface that is planar, wherein the powder removal member comprises an opening for removing powder material from the powder bed; an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object; a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
-
-
17. A system for forming a three-dimensional object, comprising:
-
a powder dispenser that dispenses a powder material to form at least a portion of a powder bed adjacent to the powder dispenser, which powder bed comprises a first exposed surface; a powder removal member disposed above the powder bed and separated from the exposed surface of the powder bed by a gap, wherein the powder removal member planarizes the first exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a second exposed surface that is planar, which powder removal member comprises an opening for removing powder material from the powder bed; an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object; a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface. - View Dependent Claims (18, 19, 20)
-
-
21. A system for forming a three-dimensional object, comprising:
-
a powder dispenser that dispenses a powder material to form at least a portion of a powder bed adjacent to the powder dispenser, which powder bed comprises a first exposed surface; a powder removal member disposed above the powder bed, wherein the powder removal member planarizes the first exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a second exposed surface that is planar, which powder removal member comprises an opening for removing powder material from the powder bed; a powder reservoir that is (i) flowably connected to the powder removal member and (ii) accepts powder material from the powder removal member, which powder reservoir comprises an opening that allows continuous removal of powder material from the powder reservoir during operation of the powder removal member; an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object; a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface. - View Dependent Claims (22, 23, 24)
-
-
25. A system for forming a three-dimensional object, comprising:
-
a powder dispenser that dispenses a powder material to form at least a portion of a powder bed adjacent to the powder dispenser, which powder bed comprises a first exposed surface; a powder leveling member disposed adjacent to the first exposed surface of the powder bed, wherein the powder leveling member shears the first exposed surface of the powder bed to form a second exposed surface, wherein the powder leveling member comprises a scoop or lift; a powder removal member disposed adjacent to the powder bed, wherein the powder removal member planarizes the second exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a third exposed surface that is planar, which powder removal member comprises an opening for removing powder material from the powder bed; an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object; a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface. - View Dependent Claims (26, 27, 28, 29)
-
Specification