Systems and methods are disclosed for forming a three-dimensional object using additive manufacturing. One method includes depositing a first amount of powder material onto a powder print bed of a printing system, spreading the first amount of powder material across the powder print bed to form a first layer, measuring a density of powder material within the powder print bed, and adjusting a parameter of the printing system based on the measured density of the powder material within the powder print bed.

A method of producing a three-dimensionally shaped object includes a step of equipping an additive manufacturing apparatus with a plate, a step of forming a support portion by depositing raw material powder on the plate and radiating light, a step of forming a three-dimensionally shaped object by depositing raw material powder on the support portion and radiating light, and a step of separating the three-dimensionally shaped object from the support portion. In the step of forming the support portion, a low-density support portion and a high-density support portion are formed. The low-density support portion has a lower density than a three-dimensionally shaped portion formed in the step of forming the three-dimensionally shaped object. The high-density support portion has a higher density than the low-density support portion.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A method for the generative production of a three-dimensional component includes providing a metallic starting material in the form of a powder bed in a substantially horizontal starting plane, supplying a process gas to the starting material, melting the starting material by a heat source, repeating the above steps, wherein at least a portion of the process gas is supplied through the powder bed. A related device is also provided.

The cost required to shape a three-dimensional laminated and shaped object is suppressed. A three-dimensional laminating and shaping apparatus for shaping a three-dimensional laminated and shaped object by irradiating a powder with a high-energy beam includes a laminating and shaping data acquirer that acquires laminating and shaping data to be used for laminating and shaping of the three-dimensional laminated and shaped object, an attribute information acquirer that acquires attribute information of the powder to be used for laminating and shaping of the three-dimensional laminated and shaped object, a model generator that generates, based on the laminating and shaping data and the attribute information, a circuit pattern model for removing electrons from the powder electrically charged by irradiation with the high-energy beam, and a circuit pattern shaping unit that shapes a circuit pattern based on the generated circuit pattern model.

According to one example, there is provided a 3D printing build unit comprising a build chamber, a build platform, and a heating element controllable to heat a portion of the contents of the build chamber to a temperature at or above a curing temperature whilst maintaining upper layers of the build chamber at or below a printing temperature.

A fabrication device includes a build surface to receive layers of material for production of a 3-dimensional solid representation of a digital model and an imaging component to bind respective portions of the build material into cross sections representative of portions of data contained in the digital model. The imaging component may be a programmable planar light source utilizing a micropixelation system and refractive pixel shifting mechanism, or other imaging system. The device may include a system for controlling the density of the printed part. The object may be a powder composite component using any of a variety of powder materials or a plastic component. The object may be further post-processed to produce a high precision metal or ceramic component.

A fabrication device includes a build surface to receive layers of material for production of a 3-dimensional solid representation of a digital model and an imaging component to bind respective portions of the build material into cross sections representative of portions of data contained in the digital model. The imaging component may be a programmable planar light source utilizing a micropixelation system and refractive pixel shifting mechanism, or other imaging system. The device may include a system for controlling the density of the printed part. The object may be a powder composite component using any of a variety of powder materials or a plastic component. The object may be further post-processed to produce a high precision metal or ceramic component.

Provided is a laminated body molding method for molding a laminated body by irradiating powder fed onto a stage with a beam and thereby fusing and solidifying the powder or sintering the powder. The laminated body molding method includes: a moving distance setting step S22 of setting a moving distance of the stage to a length that is a certain proportion of a particle diameter of the powder; and a molding step S24 of molding the laminated body by repeating a process of moving the stage downward by the moving distance, feeding the powder onto the stage thus moved, and irradiating the fed powder with the beam to fuse and solidify the powder or sinter the powder. With this laminated body molding method, impairment of capabilities of the laminated body can be prevented.