A powder bed fusion apparatus for building an object in a layer-by-layer manner includes a build platform movable within a build sleeve to define a build volume, a layer formation device for forming layers of powder across the build volume in a working plane and an irradiation device for irradiating powder in the working plane to selectively fuse the powder. The powder bed fusion apparatus further includes a mechanical manipulator arranged to engage with the object and/or a build substrate, to which the object is attached, to tilt the object in a raised position above the working plane such that powder is freed from the object and deposited at a location above the working plane and/or into the build volume.

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.

An additive manufacturing machine is provided. The additive manufacturing machine includes a build unit including a powder dispenser assembly defining a powder reservoir that receives additive powder; a dosing rate measurement device in communication with the powder dispenser assembly, wherein the dosing rate measurement device measures a dosing rate of the additive powder in-situ; and a controllable device operably coupled to the build unit and including one or more processors configured to execute a program to cause the controllable device to adjust the dosing rate of the additive powder based on the dosing rate measured by the dosing rate measurement device.

A method for additive fabrication by 3D printing includes processing model data representing material transition boundaries of an object to be printed to form build data for use in controlling printing of a plurality of successive layers to form the object, the build data comprising, for each location of a plurality of locations in a two-dimensional arrangement, material transition data for representing heights of material transitions in a third dimension, and repeating for each layer of the plurality of successive layers, receiving surface height data representing a height of a partial fabrication of the object at respective locations of a plurality of locations on a surface of the partial fabrication for each location of the plurality of locations, using the height at the location to access the material transition data corresponding to the location in the build data, and using the material transition data to determine material to be deposited at that location, and causing emission of the determined material at each location of the plurality of locations, thereby causing printing of the layer.

A method for additive fabrication by 3D printing includes processing model data representing material transition boundaries of an object to be printed to form build data for use in controlling printing of a plurality of successive layers to form the object, the build data comprising, for each location of a plurality of locations in a two-dimensional arrangement, material transition data for representing heights of material transitions in a third dimension, and repeating for each layer of the plurality of successive layers, receiving surface height data representing a height of a partial fabrication of the object at respective locations of a plurality of locations on a surface of the partial fabrication for each location of the plurality of locations, using the height at the location to access the material transition data corresponding to the location in the build data, and using the material transition data to determine material to be deposited at that location, and causing emission of the determined material at each location of the plurality of locations, thereby causing printing of the layer.

A laser-assisted microfluidics manufacturing process has been developed for the fabrication of additively manufactured structures. Roll-to-roll manufacturing is enhanced by the use of a laser-assisted electrospray printhead positioned above the flexible substrate. The laser electrospray printhead sprays microdroplets containing nanoparticles onto the substrate to form both thin-film and structural layers. As the substrate moves, the nanoparticles are sintered using a laser beam directed by the laser electrospray printhead onto the substrate.

A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.

A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.

Disclosed are powder mixtures for use in the manufacture of three dimensional objects. In the respective powder mixtures, a first material includes an aluminium alloy or a mixture of elemental precursors thereof, and is in powder form. The second material includes a metal powder of Zr and/or Hf. By the addition of the second material, it is possible to prepare three dimensional objects with high ultimate tensile strength and yield strength by additive manufacturing. Further disclosed are processes for the preparation of corresponding powder mixtures and three dimensional objects, the three dimensional objects themselves, devices for implementing the processes, and uses of the powder mixture.

A system for manufacturing assembly units. The system includes a component platform that is movably situated in a conveying direction, at least one layering unit for applying a layer, and at least one irradiation unit, which is situated downstream from the layering unit in the conveying direction of the component platform for selectively irradiating the layer for generatively assembling the layer.