A method for forming a multi-material part by selective laser melting includes the following steps. Modeling is performed by regularly distributing and arraying a combination of materials that meets forming requirements such that a part model is designed. The designed part model is subjected to a dimension compensation, a shape compensation, a chamfering setting, a margin design and a design of a process support to obtain a process model. The obtained process model is sliced into a series of layers. Type, distribution and boundary information of materials in each layer are collected to generate a control file. All materials required for part forming are loaded into an additive manufacturing equipment. After a state of the additive manufacturing equipment meets forming requirements, a part is formed under the control of the generated control file. Post-processing is performed after the part is formed.

The disclosure relates to a method for forming a metal article by additive manufacturing and related apparatus for performing the method. A metal particle suspension including a UV-curable polymeric resin liquid medium, and metal particles distributed throughout the liquid medium is deposited and cured by spatially selective exposure to UV radiation in a layer-by-layer process. Metal particle size can be selected in combination with the applied layer thickness to ensure complete cure throughout the applied layer while providing a high print speed and high spatial resolution. Intermittent or periodic partial curing of an applied layer can be used to maintain a homogeneous distribution of metal particles in the applied layer prior to full curing. The final product is achieved after sintering, which removes the cured binder in a debinding step and also provides the desired final article at close to the full density.

The disclosure relates to a method for forming a metal article by additive manufacturing and related apparatus for performing the method. A metal particle suspension including a UV-curable polymeric resin liquid medium, and metal particles distributed throughout the liquid medium is deposited and cured by spatially selective exposure to UV radiation in a layer-by-layer process. Metal particle size can be selected in combination with the applied layer thickness to ensure complete cure throughout the applied layer while providing a high print speed and high spatial resolution. Intermittent or periodic partial curing of an applied layer can be used to maintain a homogeneous distribution of metal particles in the applied layer prior to full curing. The final product is achieved after sintering, which removes the cured binder in a debinding step and also provides the desired final article at close to the full density.

The invention comprises a 3D printer for additively manufacturing a multilayer component. The 3D printer comprises at least two separate dispensers (2) coating a conveyor belt (3) with respectively different raw material, a manufacturing unit in which at least part of the raw material is added to the component (8) as a new layer, at least two separate recovery devices (12) for selectively recovering the respectively different raw material, which is not consumed when a layer is added to the component (8), and returning the raw material to the respective associated dispenser (2) and conveyor belt (3) which transports the raw material from the dispenser (2) to the manufacturing unit and further to the recovery device (12) in the lateral direction.

The invention comprises a 3D printer for additively manufacturing a multilayer component. The 3D printer comprises at least two separate dispensers (2) coating a conveyor belt (3) with respectively different raw material, a manufacturing unit in which at least part of the raw material is added to the component (8) as a new layer, at least two separate recovery devices (12) for selectively recovering the respectively different raw material, which is not consumed when a layer is added to the component (8), and returning the raw material to the respective associated dispenser (2) and conveyor belt (3) which transports the raw material from the dispenser (2) to the manufacturing unit and further to the recovery device (12) in the lateral direction.

In one example, a system for loading a build material powder supply receptacle for a 3D printer includes a reconditioner having a container and a heater to burn unwanted residue from used build material powder in the container, to form reconditioned build material powder, a conveyor operatively connected to the reconditioner to convey used build material powder to the container, and a dispenser operatively connected to the reconditioner to dispense reconditioned build material powder from the container into the supply receptacle.

In one example, a system for loading a build material powder supply receptacle for a 3D printer includes a reconditioner having a container and a heater to burn unwanted residue from used build material powder in the container, to form reconditioned build material powder, a conveyor operatively connected to the reconditioner to convey used build material powder to the container, and a dispenser operatively connected to the reconditioner to dispense reconditioned build material powder from the container into the supply receptacle.

In one example, a system for loading a build material powder supply receptacle for a 3D printer includes a reconditioner having a container and a heater to burn unwanted residue from used build material powder in the container, to form reconditioned build material powder, a conveyor operatively connected to the reconditioner to convey used build material powder to the container, and a dispenser operatively connected to the reconditioner to dispense reconditioned build material powder from the container into the supply receptacle.

A device for metering one or more powder(s) (A, B) to produce a flow (23) of powder(s) and of a carrier gas at a given volume flow rate, comprises: ⋅at least a first source (25) suitable for supplying a first flow (27) comprising a first powder (A) and a first carrier gas (G1) substantially at the given volume flow rate, ⋅a source (33) of a carrier gas suitable for supplying an adjustment carrier gas flow (35) substantially at the given volume flow rate, ⋅an outlet junction (49) for emitting said flow of powder(s) and of carrier gas, ⋅a first proportional valve (59), ⋅an adjustment proportional valve (75), and ⋅a control system (21) suitable for controlling at least the first proportional valve and the adjustment proportional valve so that the flow of powder(s) and of carrier gas has a volume flow rate substantially equal to the given volume flow rate.

Certain examples relate to a material management station for use in an additive manufacturing process. In these examples a metering system is applied to measure the amount of build material transported into the material management station from refillable containers. Data describing the metered amount of build material is communicated over a data communication network and remotely compared to an allowance of usage stored in an administration system. Control messages are communicated to the material management station preventing or allowing further use of the build material in line with the allowance usage.