Apparatus (1) for manufacturing a three-dimensional object from a powder, the apparatus comprising: a work surface (170); a build bed (201) having a build area (190), the build area (190) being comprised within the work surface (170), wherein successive layers of said three-dimensional object are formed in the build bed (201); a first powder supply module (2) fixedly arranged on a first side of the work surface (170), outward from a first side of the build bed (201); a second powder supply module (3) fixedly arranged on a second side of the work surface (170), outward from a second side of the build bed (201); a first powder distribution sled (300) operable to distribute powder dosed to the work surface (170) from the first powder supply module (2) while moving in a first direction from the first side of the work surface (170) towards the second side of the work surface (170), and from the second powder supply module (3) while moving in a second direction from the second side of the work surface (170) towards the first side of the work surface (170), so as to form a layer of powder within the build area (190), the first powder distribution sled (300) being driveable along a first axis across the build area (190); and a print sled (350) operable to deposit a pattern of fluid onto the layer of powder within the build area (170) to define the cross section of said object in said layer, the print sled (350) being driveable along a second axis across the build area (170); wherein the first powder distribution sled (300) comprises a first powder distribution device (320) for distributing the powder; wherein the print sled (350) comprises one or more droplet deposition heads (370) for depositing the fluid, a first radiation source assembly located on one side of the one or more droplet deposition heads (370), and a second radiation source assembly located on the other side of the one or more droplet deposition heads (370); and wherein the first powder distribution sled (300) further comprises a third radiation source assembly. Also provided a method of manufacturing a three-dimensional object from a powder, using apparatus according to the first aspect of the invention to form each layer of said object.

A device for fabricating a three-dimensional fabrication object includes a fabrication part, a flattening member to place powder in the fabrication part to form an excessively thick powder layer and remove the powder on the top surface side of the excessively thick powder layer multiple times to obtain a powder layer while moving in a direction orthogonal to a lamination direction of the powder layer, and a fabrication unit to bind the powder in the powder layer to form a laminar fabrication object, (wherein the laminar fabrication object is formed repeatedly to fabricate the three-dimensional fabrication object), wherein the amount of a layer thickness of the powder removed for the last time is less than that for any other time.

A device for fabricating a three-dimensional fabrication object includes a fabrication part, a flattening member to place powder in the fabrication part to form an excessively thick powder layer and remove the powder on the top surface side of the excessively thick powder layer multiple times to obtain a powder layer while moving in a direction orthogonal to a lamination direction of the powder layer, and a fabrication unit to bind the powder in the powder layer to form a laminar fabrication object, (wherein the laminar fabrication object is formed repeatedly to fabricate the three-dimensional fabrication object), wherein the amount of a layer thickness of the powder removed for the last time is less than that for any other time.

This build material spreading apparatus for additive manufacturing, includes a movable spreader, a build material dispenser, and a controller to calibrate the amount of build material needed to form a layer. The controller controls the build material dispenser to dispense a predetermined amount of build material. The controller controls the movable spreader to spread the dispensed build material to form a layer. The controller determines an amount of build material remaining after spreading. The controller modifies, based on the determined amount of remaining build material, the predetermined amount of build material to be subsequently provided by the build material dispenser.

Methods and systems for additive manufacturing can include a modular spreader unit including multiple spreaders that collectively span the width of a large build area. The spreaders can be arranged in offset rows so that spreaders in a second row cover gaps between spreaders in a first row. The spreaders can be secured with quick release mechanisms for rapid replacement and adjustment during service intervals.

Methods and systems for additive manufacturing can include a modular spreader unit including multiple spreaders that collectively span the width of a large build area. The spreaders can be arranged in offset rows so that spreaders in a second row cover gaps between spreaders in a first row. The spreaders can be secured with quick release mechanisms for rapid replacement and adjustment during service intervals.

Methods and systems for additive manufacturing can include a modular spreader unit including multiple spreaders that collectively span the width of a large build area. The spreaders can be arranged in offset rows so that spreaders in a second row cover gaps between spreaders in a first row. The spreaders can be secured with quick release mechanisms for rapid replacement and adjustment during service intervals.

Some examples include a method of operating an additive manufacturing machine including spreading a build material in a first direction across a build surface to form a layer, the layer having a thickness, decreasing a distance between a spread mechanism and the build surface, and translating the spread mechanism in a second direction opposite the first direction over the build surface to reduce the thickness of the layer.

Some examples include a method of operating an additive manufacturing machine including spreading a build material in a first direction across a build surface to form a layer, the layer having a thickness, decreasing a distance between a spread mechanism and the build surface, and translating the spread mechanism in a second direction opposite the first direction over the build surface to reduce the thickness of the layer.

A build material dispensing device may include a material spreader to spread an amount of build material along a build platform, and at least one hopper for dispensing the build material. The at least one hopper dispenses a plurality of doses of the build material in front of the progression of the material spreader as the material spreader is moved over the build platform.