The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for the production of at least one desired 3D object. The 3D printer system (e.g., comprising a processing chamber, build module, or an unpacking station) described herein may retain a desired (e.g., inert) atmosphere around the material bed and/or 3D object at multiple 3D printing stages. The 3D printer described herein comprises one or more build modules that may have a controller separate from the controller of the processing chamber. The 3D printer described herein comprises a platform that may be automatically constructed. The invention(s) described herein may allow the 3D printing process to occur for a long time without operator intervention and/or down time.

In one example, a print head drop detector (202) is described. The print head drop detector (202) comprises a sampling volume and a fan (208) to cause an airflow though the sampling volume (206). Detection apparatus to detect the presence of non-gaseous material within the sampling volume is also provided.

A method and apparatus for manufacturing an equiaxed crystal aluminum alloy cast ingot by using additive manufacturing and rapid solidification techniques are provided. The apparatus comprises: a metal heating mechanism and a negative pressure cooling mechanism. The metal heating mechanism is located above the negative pressure cooling mechanism and is connected thereto by a nozzle. The negative pressure cooling mechanism comprises a vacuum chamber having an air inlet hole and an air outlet hole, and a three-dimensional moving ingot mechanism disposed inside the vacuum chamber. The three-dimensional moving ingot mechanism comprises a moving ingot and a two-dimensional moving platform vertically connected to the moving ingot. A water cooling mechanism is disposed outside the moving ingot, and the moving ingot is driven by a precision motor to precisely move up and down.

A method and apparatus for manufacturing an equiaxed crystal aluminum alloy cast ingot by using additive manufacturing and rapid solidification techniques are provided. The apparatus comprises: a metal heating mechanism and a negative pressure cooling mechanism. The metal heating mechanism is located above the negative pressure cooling mechanism and is connected thereto by a nozzle. The negative pressure cooling mechanism comprises a vacuum chamber having an air inlet hole and an air outlet hole, and a three-dimensional moving ingot mechanism disposed inside the vacuum chamber. The three-dimensional moving ingot mechanism comprises a moving ingot and a two-dimensional moving platform vertically connected to the moving ingot. A water cooling mechanism is disposed outside the moving ingot, and the moving ingot is driven by a precision motor to precisely move up and down.

A three-dimensional shaped object using a plurality of materials can be shaped, and replenishment of the materials is implemented during shaping without stopping an apparatus. A three-dimensional laminating and shaping apparatus includes a shaping chamber in which a three-dimensional laminated and shaped object is shaped, at least two material spreaders that are provided in the shaping chamber and spread materials of the three-dimensional laminated and shaped object, at least two material suppliers that supply the materials to the material spreaders, a controller that controls movements of the material spreaders and the material suppliers, and a beam irradiator that irradiates the materials with a beam. The material spreaders and the material suppliers are respectively paired, and the controller controls the movements of the material spreaders and the material suppliers so that each of the material spreaders is supplied, at a predetermined timing, with the material from a paired one of the material suppliers.

A three-dimensional modeling device includes a modeling section supplied with a material including a metal powder, a laser source adapted to emit a laser used to sinter or melt the metal powder, and an optical component through which the laser emitted from the laser source passes in the midway to the material on the modeling section. The optical component is provided with a first area, which faces to the modeling section, and through which the laser passes, and a second area higher in surface free energy than the first area is disposed in at least a part of a periphery of the first area.

An apparatus (1) for manufacturing a three-dimensional object from particulate material, the apparatus comprising: a work space (100) bounded by a first side wall (100A) on a first side of the work space, and a second side wall (100B) on a second side of the work space, the first side wall opposing the second side wall; a build bed (170) having a build bed surface (160), the build bed surface being comprised in the floor of the work space and having a first edge (160′) on the first side of the work space, towards the first side wall, and a second edge (160″) on the second side of the work space, towards the second side wall; a first gas inlet (101A) at or near the first side wall; a second gas inlet (101B) at or near the second side wall; a first gas outlet (102A) above the floor (100C) of the work space, the position of the first gas outlet being coincident with the first edge of the build bed surface, or between the first edge of the build bed surface and the first gas inlet; and a second gas outlet (102B) above the floor of the work space, the position of the second gas outlet being coincident with the second edge of the build bed surface, or between the second edge of the build bed surface and the second gas inlet; wherein the first gas outlet is positioned higher in the work space than the first gas inlet, and the second gas outlet is positioned higher in the work space than the second gas inlet; and wherein one or more flow devices (210, 211, 212) are operable to create first and second gas flows between the first gas inlet and the first gas outlet, and between the second gas inlet and the second gas outlet, respectively, such as to create respective first and second gas curtains on the first and second sides of the work space in use.

Selective laser solidification apparatus is described that includes a powder bed onto which a powder layer can be deposited and a gas flow unit for passing a flow of gas over the powder bed along a predefined gas flow direction. A laser scanning unit is provided for scanning a laser beam over the powder layer to selectively solidify at least part of the powder layer to form a required pattern. The required pattern is formed from a plurality of stripes or stripe segments that are formed by advancing the laser beam along the stripe or stripe segment in a stripe formation direction. The stripe formation direction is arranged so that it always at least partially opposes the predefined gas flow direction. A corresponding method is also described.

An additively manufactured assembly including an additively manufactured component with an edge oriented with respect to a recoater blade direction and an non-contact support that does not form a part of the additively manufactured component, the additively manufactured support located adjacent the edge. A method of additively manufacturing a component includes additively manufacturing an component with an edge oriented with respect to a recoater blade direction simultaneous with additively manufacturing an non-contact support that does not form a part of the component, the additively manufactured support located adjacent the edge.

An additively manufactured assembly including an additively manufactured component with an edge oriented with respect to a recoater blade direction and an non-contact support that does not form a part of the additively manufactured component, the additively manufactured support located adjacent the edge. A method of additively manufacturing a component includes additively manufacturing an component with an edge oriented with respect to a recoater blade direction simultaneous with additively manufacturing an non-contact support that does not form a part of the component, the additively manufactured support located adjacent the edge.