A fabricated object manufactured from powder contained in a container of a fabrication apparatus is provided. The fabricated object satisfies the following relationship d>d′, where d (μm) denotes a number average diameter of the powder contained in the container and d′ (μm) denotes a number average diameter of the powder included in the fabricated object.

A fabricated object manufactured from powder contained in a container of a fabrication apparatus is provided. The fabricated object satisfies the following relationship d>d′, where d (μm) denotes a number average diameter of the powder contained in the container and d′ (μm) denotes a number average diameter of the powder included in the fabricated object.

In an example of a method for three-dimensional (3D) printing, a build material composition is applied to form a build material layer. The build material composition includes a polymeric or polymeric composite build material, and a precipitating agent. Based on a 3D object model, a fusing agent is selectively applied on at least a portion of the build material composition. The fusing agent includes a radiation absorber, which the precipitating agent precipitates. The build material composition is exposed to radiation to fuse the at least the portion to form a layer of a 3D part.

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

The invention relates to a method for producing three-dimensional components (14) by successively solidifying layers of a powder construction material (9) which can be solidified by means of electromagnetic radiation (18), in particular bundled radiation such as laser radiation or electron radiation, at the locations corresponding to the respective cross-section of the component (14), in particular an SLM (selective laser melting) or SLS (selective laser sintering) method. A device (1) comprising a support device (7), the height of which can be adjusted within a construction chamber (6), is provided for supporting the component (14), comprising a coating device (12) for applying layers of the construction material (9) onto the support device or onto a previously formed layer and comprising an irradiating device (15) for irradiating layers of the construction material (9) in some regions in order to solidify the layers. A surface (13) section to be coated is scanned with respect to the evenness of the section prior to the application of a new layer, and in the event of an unevenness which exceeds a known tolerance range, the unevenness is removed or leveled out.

A three-dimensional object fabrication method of the present disclosure includes forming a fabrication layer including a fabrication material, applying a fabrication liquid to the fabrication layer, flattening the fabrication layer, monitoring a scattering condition of the fabrication material in the forming and the flattening, and adjusting at least one of the forming and the flattening, based on a monitoring result of the scattering condition in the monitoring.

A three-dimensional object fabrication method of the present disclosure includes forming a fabrication layer including a fabrication material, applying a fabrication liquid to the fabrication layer, flattening the fabrication layer, monitoring a scattering condition of the fabrication material in the forming and the flattening, and adjusting at least one of the forming and the flattening, based on a monitoring result of the scattering condition in the monitoring.

Described herein are compositions, methods, and systems for printing metal three-dimensional objects. In an example, described is a composition for three-dimensional printing comprising: a metal powder build material, wherein the metal powder build material has an average particle size of from about 10 μm to about 250 μm; and a binder fluid comprising: an aqueous liquid vehicle, and latex polymer particles dispersed in the aqueous liquid vehicle, wherein the latex polymer particles have an average particle size of from about 10 nm to about 300 nm.

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.