A printing apparatus is for printing a three-dimensional object. The apparatus includes an operative surface, an energy source for emitting at least one energy beam onto the operative surface and a powder dispensing mechanism for depositing powder onto the operative surface, the powder being adapted to be melted by the or each energy beam. The powder dispensing mechanism is configured to deposit multiple layers of powder onto the operative surface simultaneously.

An additive manufacturing apparatus may include a process chamber, a coating device, a shielding device, and a guiding device. The process chamber may include first and second working plane areas. The first working plane area may include a construction plane, and the second working plane area may house at least a part of the guiding device. The coating device may include a coating element assembly group that is, movably supported relative to the construction plane by the guiding device, and at least one coating element configured to form construction material layers in the construction plane. The shielding device may shield the second working plane area from intrusion of construction material or impurities from the first working plane area. The shielding device may include a shielding band, and the shielding band may be coupled for movement with the coating element assembly group. The shielding band may be guided movably along a plurality of supporting points that define an interior region of the second working plane area, and the guiding device may be arranged or formed above the first working plane area.

An additive manufacturing apparatus may include a process chamber, a coating device, a shielding device, and a guiding device. The process chamber may include first and second working plane areas. The first working plane area may include a construction plane, and the second working plane area may house at least a part of the guiding device. The coating device may include a coating element assembly group that is, movably supported relative to the construction plane by the guiding device, and at least one coating element configured to form construction material layers in the construction plane. The shielding device may shield the second working plane area from intrusion of construction material or impurities from the first working plane area. The shielding device may include a shielding band, and the shielding band may be coupled for movement with the coating element assembly group. The shielding band may be guided movably along a plurality of supporting points that define an interior region of the second working plane area, and the guiding device may be arranged or formed above the first working plane area.

Examples of methods for monitoring additive manufacturing by an electronic device are described herein. In some examples, a predicted thermal image is calculated for a layer. In some examples, a captured thermal image is obtained for the layer. In some examples, a risk score is calculated for the layer based on the predicted thermal image and the captured thermal image. In some examples, a mitigation operation is performed in response to determining that the risk score is outside of a threshold range.

A method of manufacturing a three-dimensionally shaped object includes a first powder-layer forming process in which a first portion of at least one thickness determining member forms a powder layer by moving in contact with powder, a solidifying process in which a solidified portion is formed in the powder layer formed in the first powder-layer forming process, a second powder-layer forming process, performed after the solidifying process, in which a second portion of the at least one thickness determining member forms a powder layer by moving in contact with the powder, and a renewal process performed between the first powder-layer forming process and the second powder-layer forming process. In the renewal process, the portion having been in contact with the powder is renewed such that the second portion is different from the first portion.

A method of manufacturing a three-dimensionally shaped object includes a first powder-layer forming process in which a first portion of at least one thickness determining member forms a powder layer by moving in contact with powder, a solidifying process in which a solidified portion is formed in the powder layer formed in the first powder-layer forming process, a second powder-layer forming process, performed after the solidifying process, in which a second portion of the at least one thickness determining member forms a powder layer by moving in contact with the powder, and a renewal process performed between the first powder-layer forming process and the second powder-layer forming process. In the renewal process, the portion having been in contact with the powder is renewed such that the second portion is different from the first portion.

A three-dimensional printing system includes a build platform, a movement mechanism, a coating module, a consolidation module, and a controller. The controller is configured to (1) operate the movement mechanism and the coating module to deposit a new powder layer over an upper surface of the build platform or powder, (2) operate the consolidation module to selectively consolidate the new powder layer, and (3) repeat (1) and (2) until a three-dimensional article is fabricated from a plurality of layers. Step (1) includes, at least one of the plurality of layers (a) operate the movement mechanism and the coating module to deposit a first sublayer of powder having a thickness T1 over the upper surface, and (b) operate the movement mechanism and the coating module to deposit a second sublayer of powder having at thickness T2 over the first sublayer of powder. T2 is less than 20% of T1.

A three-dimensional printing system includes a build platform, a movement mechanism, a coating module, a consolidation module, and a controller. The controller is configured to (1) operate the movement mechanism and the coating module to deposit a new powder layer over an upper surface of the build platform or powder, (2) operate the consolidation module to selectively consolidate the new powder layer, and (3) repeat (1) and (2) until a three-dimensional article is fabricated from a plurality of layers. Step (1) includes, at least one of the plurality of layers (a) operate the movement mechanism and the coating module to deposit a first sublayer of powder having a thickness T1 over the upper surface, and (b) operate the movement mechanism and the coating module to deposit a second sublayer of powder having at thickness T2 over the first sublayer of powder. T2 is less than 20% of T1.

Various methods of additive layer manufacturing, and objects obtainable by such manufacturing, are disclosed. In particular, there is provided a method of additive layer manufacturing comprising depositing a layer of a material on a surface, and controlling the deposition to vary a material property of the material within the layer. There is also provided a method of additive layer manufacturing comprising depositing at least one layer of material on a sacrificial layer, the layer of material having a thickness of 400 microns or less, wherein the sacrificial layer is located on a base surface.

An apparatus, system and method for additive manufacturing. The apparatus, system and method may include a solution dispenser comprising a carrier having embedded therein particles having a size of about 1-5 microns; a jet suitable to disperse the solution from the dispenser; and a tunable heat filter suitable to burn off the carrier, and make molten the particles, as the solution passes therethrough; wherein an additive manufacturing print build receives the molten particles.