A data generation program includes instructions of: acquiring three-dimensional data representing a three-dimensional shape of a three-dimensional product; acquiring an arrangement condition for arranging a support member to the three-dimensional product; setting an extending direction, a width direction, and a height direction of the support member; adding a cutting margin of a particular thickness to a cutting surface of the three-dimensional product at one side in the height direction; setting the support member in accordance with the arrangement condition, one end of the support member in the extending direction being connected to the cutting margin added to the three-dimensional product; setting a beam, the beam being spaced from the three-dimensional product having the cutting margin in the extending direction, the beam extending in the width direction; generating three-dimensional modeling data for modeling a modeled object by using a three-dimensional modeling apparatus; and outputting the three-dimensional modeling data.

Methods, systems, and apparatus, for hybrid additive manufacturing of parts. In one aspect, a method includes providing a workpiece and manufacturing multiple additive layers on a surface of the workpiece. Manufacturing each of the multiple additive layers includes forming one or more formed layers on a surface of the workpiece by depositing a quantity of powder material on a growth surface, the growth surface inclusive of at least one of a first surface of the workpiece and a second surface of a previously formed layer, and applying a first amount of energy to the quantity of powder material to fuse the particles of the powder material into a formed layer fused to the growth surface, where the formed layer includes a formed surface, and further applying a secondary process to a particular area of the formed surface of the one or more formed layers on the workpiece.

Methods, systems, and apparatus, for hybrid additive manufacturing of parts. In one aspect, a method includes providing a workpiece and manufacturing multiple additive layers on a surface of the workpiece. Manufacturing each of the multiple additive layers includes forming one or more formed layers on a surface of the workpiece by depositing a quantity of powder material on a growth surface, the growth surface inclusive of at least one of a first surface of the workpiece and a second surface of a previously formed layer, and applying a first amount of energy to the quantity of powder material to fuse the particles of the powder material into a formed layer fused to the growth surface, where the formed layer includes a formed surface, and further applying a secondary process to a particular area of the formed surface of the one or more formed layers on the workpiece.

Methods for repurposing waste materials, such as aluminum powder, are disclosed. A method in accordance with an aspect of the present disclosure may comprise collecting a material in a container, the material comprising oxidized aluminum powder, processing the material, which includes heating the material to melt at least a portion of the oxidized aluminum powder, and forming the processed material into at least one component.

A superhard material-containing object is configured to have a controlled and repeatable three-dimensional geometry and/or shape. The object further includes a desired three-dimensional spatial variation in microstructure, grain size and/or composition. The superhard material is selected from the group consisting of diamond, boron-doped diamond and cubic boron nitride. A process for production of a superhard material-containing object from a powder of a superhard material, a binder and an optional additive, includes the steps of: (a) producing a feedstock of the superhard material and a polymer binder; (b) extruding one or more filaments from a granulated superhard material-binder feedstock; (c) preparing a printed superhard material-containing object using the one or more filaments; (d) subjecting the printed object to debinding to prepare a debindered object; and (e) sintering the debindered printed object to produce the superhard material-containing object.

A superhard material-containing object is configured to have a controlled and repeatable three-dimensional geometry and/or shape. The object further includes a desired three-dimensional spatial variation in microstructure, grain size and/or composition. The superhard material is selected from the group consisting of diamond, boron-doped diamond and cubic boron nitride. A process for production of a superhard material-containing object from a powder of a superhard material, a binder and an optional additive, includes the steps of: (a) producing a feedstock of the superhard material and a polymer binder; (b) extruding one or more filaments from a granulated superhard material-binder feedstock; (c) preparing a printed superhard material-containing object using the one or more filaments; (d) subjecting the printed object to debinding to prepare a debindered object; and (e) sintering the debindered printed object to produce the superhard material-containing object.

In a three-dimensional printing method example, a liquid functional agent is selectively applied. The liquid functional agent includes an alloying agent. A metallic build material is applied. The liquid functional agent is selectively applied before the metallic build material, after the metallic build material, or both before and after the metallic build material. The liquid functional agent patterns the metallic build material to form a composite layer. At least some of the metallic build material is exposed to energy to melt the at least some of the metallic build material to form a layer. Upon contact or after energy exposure, the alloying agent and the build material alter a composition of the composite layer.

In a three-dimensional printing method example, a liquid functional agent is selectively applied. The liquid functional agent includes an alloying agent. A metallic build material is applied. The liquid functional agent is selectively applied before the metallic build material, after the metallic build material, or both before and after the metallic build material. The liquid functional agent patterns the metallic build material to form a composite layer. At least some of the metallic build material is exposed to energy to melt the at least some of the metallic build material to form a layer. Upon contact or after energy exposure, the alloying agent and the build material alter a composition of the composite layer.

Porous and microporous parts prepared by additive manufacturing as disclosed herein are useful in medical and non-medical applications. The parts are prepared from a composition containing both a solvent soluble component and a solvent insoluble component. After a part is printed by an additive manufacturing process it is exposed to solvent to extract solvent soluble component away from the printed part, resulting in a part having surface cavities.

Porous and microporous parts prepared by additive manufacturing as disclosed herein are useful in medical and non-medical applications. The parts are prepared from a composition containing both a solvent soluble component and a solvent insoluble component. After a part is printed by an additive manufacturing process it is exposed to solvent to extract solvent soluble component away from the printed part, resulting in a part having surface cavities.