A three-dimensional (3-D) printer includes build and support material development stations positioned to transfer layers of build and support materials to an intermediate transfer surface. A platen having a flat surface is positioned to contact the intermediate transfer surface. The intermediate transfer surface transfers a layer of the build and support materials to the flat surface of the platen as the platen contacts one of the layers on the intermediate transfer surface. A dispenser is positioned to deposit a leveling material on the layer on the platen, and a mechanical planer is positioned to contact and level the leveling material on the layer on the platen to make the top of the leveling material parallel to the flat surface of the platen.

A composition suitable for 3D printing. The composition is in the form of a filament and includes: a) a metal and/or ceramic powder: b) an organic binding phase including two parts: b1) at least one thermoplastic compound selected from thermoplastic polymers and waxes; and b2) at least one volatile organic compound which has a vapor pressure at 50° C., ranging from more than 0 bar to 0.05 bar, wherein the amount of the at least one volatile organic compound ranges from more than 0.5% to 40% (v/v) by volume relative to the total volume of the composition.

A composition suitable for 3D printing. The composition is in the form of a filament and includes: a) a metal and/or ceramic powder: b) an organic binding phase including two parts: b1) at least one thermoplastic compound selected from thermoplastic polymers and waxes; and b2) at least one volatile organic compound which has a vapor pressure at 50° C., ranging from more than 0 bar to 0.05 bar, wherein the amount of the at least one volatile organic compound ranges from more than 0.5% to 40% (v/v) by volume relative to the total volume of the composition.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

Methods and systems are described for fabricating a component using 3D printing. A 3D printed piece is created including a body of the component, a support structure, and a first sacrificial interface region coupling the body of the component to the support structure. The body of the component is formed of a first metal or ceramic material and the first sacrificial interface region is formed at least partially of a second metal or ceramic material. The body of the component is then separated from the support structure by applying a chemical or electrochemical dissolution process to the 3D printed piece. Because the second metal or ceramic material is less resistant to the dissolution process than the first metal or ceramic material, the first sacrificial interface region at least partially dissolves, thereby separating the body of the metal component from the support structure, without dissolving the body of the component.

Methods and systems are described for fabricating a component using 3D printing. A 3D printed piece is created including a body of the component, a support structure, and a first sacrificial interface region coupling the body of the component to the support structure. The body of the component is formed of a first metal or ceramic material and the first sacrificial interface region is formed at least partially of a second metal or ceramic material. The body of the component is then separated from the support structure by applying a chemical or electrochemical dissolution process to the 3D printed piece. Because the second metal or ceramic material is less resistant to the dissolution process than the first metal or ceramic material, the first sacrificial interface region at least partially dissolves, thereby separating the body of the metal component from the support structure, without dissolving the body of the component.

Methods and systems are described for fabricating a component using 3D printing. A 3D printed piece is created including a body of the component, a support structure, and a first sacrificial interface region coupling the body of the component to the support structure. The body of the component is formed of a first metal or ceramic material and the first sacrificial interface region is formed at least partially of a second metal or ceramic material. The body of the component is then separated from the support structure by applying a chemical or electrochemical dissolution process to the 3D printed piece. Because the second metal or ceramic material is less resistant to the dissolution process than the first metal or ceramic material, the first sacrificial interface region at least partially dissolves, thereby separating the body of the metal component from the support structure, without dissolving the body of the component.

A method for additively manufacturing at least a portion of a component, in particular a component of a turbomachine. The method includes the following steps: a) depositing at least one powder layer of a component material in powder form layer by layer onto a component platform in the region of a buildup and joining zone; b) locally solidifying the powder layer by selectively irradiating the same using at least one high-energy beam in the region of the buildup and joining zone, forming a component layer; c) lowering the component platform by a predefined layer thickness; and d) repeating steps a) through c) until completion of the component portion or of the component. At least one contour portion of at least one component layer is irradiated in a step b1) at least once by at least one high-energy beam in a way that allows the solidified powder layer to be locally heated, but not melted, and, in a subsequent step b2), irradiated by at least one high-energy beam in a way that allows the solidified powder layer-to be locally melted in the region of the contour portion. In addition, a device for implementing such a method.

An apparatus and a process for removing a support structure from a 3D printed part, where the 3D printed part along with the support structure is placed in an acid solution and the part is surrounded by an induction heater. The acid solution is recirculated through the acid tank to prevent the acid solution from heating up too much. Small surfaces of the part are heated up by the induction heater before larger pieces are heated so that the acid will remove the smaller pieces first. After enough time, all of the support structure is removed by the acid and the heater to leave the finished 3D printed part with the support structure removed.

An apparatus and a process for removing a support structure from a 3D printed part, where the 3D printed part along with the support structure is placed in an acid solution and the part is surrounded by an induction heater. The acid solution is recirculated through the acid tank to prevent the acid solution from heating up too much. Small surfaces of the part are heated up by the induction heater before larger pieces are heated so that the acid will remove the smaller pieces first. After enough time, all of the support structure is removed by the acid and the heater to leave the finished 3D printed part with the support structure removed.