A jetted binder printing system includes a carrier substrate configured to travel along a longitudinal direction thereof, an adjustable binder printer configured to deliver an adjustable binder to the carrier substrate, a dispensing module located downstream from the adjustable binder printer on the longitudinal direction of the carrier substrate, the dispensing module including at least one powder container, the dispensing module being configured to dispense powder onto the carrier substrate, and a primary binder printer located downstream from the compaction module along the longitudinal direction of the carrier substrate. The primary binder printer includes a print head configured to print a primary binder on the dispensed powder according to a desired pattern. The primary binder is printed on a surface of the powder that is opposite a surface on which the adjustable binder is printed. The primary binder is printed to match the pattern of the adjustable binder.

A jetted binder printing system includes a carrier substrate configured to travel along a longitudinal direction thereof, an adjustable binder printer configured to deliver an adjustable binder to the carrier substrate, a dispensing module located downstream from the adjustable binder printer on the longitudinal direction of the carrier substrate, the dispensing module including at least one powder container, the dispensing module being configured to dispense powder onto the carrier substrate, and a primary binder printer located downstream from the compaction module along the longitudinal direction of the carrier substrate. The primary binder printer includes a print head configured to print a primary binder on the dispensed powder according to a desired pattern. The primary binder is printed on a surface of the powder that is opposite a surface on which the adjustable binder is printed. The primary binder is printed to match the pattern of the adjustable binder.

The present disclosure provides various aspects for mobile and automated processing utilizing additive manufacturing and the methods for their utilization and for making material dispensing element arrays for use of the additive manufacturing device.

According to examples, a system may include a recoater and a controller. The controller may identify a structure of a surface of a layer of build material formed on a build platform and may determine whether the identified structure of the surface includes a portion that has a property that is outside of a predefined property level. Based on a determination that the portion has a property that is outside of the predefined property level, an adjustment to be applied to an operation of the recoater to achieve an intended structure of the layer and/or an intended structure of a subsequent layer may be determined and the determined adjustment on the operation of the recoater may be applied.

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.

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 three-dimensional fabrication apparatus includes a fabrication chamber and a roller. Powder is spread in layers in the fabrication chamber. Fabrication layers are formed of the powder bonded together and laminated in the fabrication chamber. The roller flattens the powder in the fabrication chamber. The roller includes a first helical groove region and a second helical groove region. The first helical groove region includes a first groove that moves the powder in the fabrication chamber in a first direction along a longitudinal axis of the roller as the roller rotates. The second helical groove region includes a second groove moves the powder in the fabrication chamber in a second direction opposite to the first direction as the roller rotates.

A three-dimensional fabrication apparatus includes a fabrication chamber and a roller. Powder is spread in layers in the fabrication chamber. Fabrication layers are formed of the powder bonded together and laminated in the fabrication chamber. The roller flattens the powder in the fabrication chamber. The roller includes a first helical groove region and a second helical groove region. The first helical groove region includes a first groove that moves the powder in the fabrication chamber in a first direction along a longitudinal axis of the roller as the roller rotates. The second helical groove region includes a second groove moves the powder in the fabrication chamber in a second direction opposite to the first direction as the roller rotates.

Process for additive manufacturing of at least one part. At least one layer of powder is deposited on a working surface using a layering device for distributing the powder mobile in translation along the surface and at least partly fusing the layer deposited using a beam of energy. The depositing and fusing steps are repeated in order to form the part by stacking of fused layers. The distribution component of the layering device is mobile in a direction substantially parallel to the direction of the length of each fused layer of the part. The depositing and fusing steps are repeated in order to form the part so that the length of the part extends along a direction substantially parallel to the stacking direction of the fused layers and so that the head of the part is oriented substantially perpendicular to the working surface.

A fabrication device includes a platform to receive layers of build material for production of a 3-dimensional solid representation of a digital model, a component to deposit layers of build material, 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 first imaging component may be a programmable planar light source or a specialized refractive rastering mechanism, or other imaging system. The platform includes an infusion system for providing photocurable resin to the component being built. The object may be a powder composite component using any of a variety of powder materials or a plastic component.