An additive manufacturing apparatus for manufacturing a three-dimensional component includes: a build plate, at least a portion of which is transparent, the build plate defining a build surface; a material depositor operable to deposit a radiant-energy-curable resin on the build surface; a stage positioned facing the build surface of the build plate and configured to hold a stacked arrangement of one or more cured layers of the resin; one or more actuators operable to change the relative positions of the build plate and the stage; a radiant energy apparatus positioned adjacent to the build plate opposite to the stage, and operable to generate and project radiant energy on the resin through the build plate in a predetermined pattern; and a cleaning apparatus operable to remove debris from the build surface. A method is provided for use of the apparatus.

A method of additively manufacturing an object includes steps of: (1) successively forming a plurality of powder layers by depositing powder; (2) selectively controlling a composition of the powder that forms each one of the plurality of powder layers; and (3) successively forming a plurality of object layers of the object by joining the powder of a portion of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers.

A powder spreading apparatus includes a hopper having a first end, a second end opposite from the first end, a front wall, a rear wall opposite from the front wall, and a floor. The front wall, the rear wall, the first end, the second end, and the floor define an interior. An impeller is disposed within the interior of the hopper. The impeller includes a plurality of circumferentially spaced flutes and is configured to rotate about an impeller axis that extends from the first end of the hopper to the second end of the hopper to deposit powder onto a print area. A spreader rod is coupled to the hopper and extends along a spreader rod axis parallel to the impeller axis. The spreader rod is configured to rotate about the spreader rod axis to smooth the powder as it is deposited onto the print area.

A powder spreading apparatus includes a hopper having a first end, a second end opposite from the first end, a front wall, a rear wall opposite from the front wall, and a floor. The front wall, the rear wall, the first end, the second end, and the floor define an interior. An impeller is disposed within the interior of the hopper. The impeller includes a plurality of circumferentially spaced flutes and is configured to rotate about an impeller axis that extends from the first end of the hopper to the second end of the hopper to deposit powder onto a print area. A spreader rod is coupled to the hopper and extends along a spreader rod axis parallel to the impeller axis. The spreader rod is configured to rotate about the spreader rod axis to smooth the powder as it is deposited onto the print area.

A method of forming an additive manufactured component comprises depositing a first layer of build material on a build platform within an additive manufacturing machine, depositing reinforcement fibers into the first layer of build material, orienting the reinforcement fibers within the first layer of build material, lowering the build platform, depositing a second layer of build material on top of the first layer of build material, depositing reinforcement fibers into the second layer of build material, and orienting the reinforcement fibers within the second layer of build material.

A system and method for autonomously creating subsequent physical objects using a 3-dimensional printer. The system includes a build platform which is ejected with a printed object adhered to it, with a replenishing mechanism to place a blank build platform into the expected build area such that printing a subsequent object may occur autonomously. The replenishing mechanism may draw from a plurality of stored blank build platforms which may be reusable in some embodiments and disposable in others.

A system and method for autonomously creating subsequent physical objects using a 3-dimensional printer. The system includes a build platform which is ejected with a printed object adhered to it, with a replenishing mechanism to place a blank build platform into the expected build area such that printing a subsequent object may occur autonomously. The replenishing mechanism may draw from a plurality of stored blank build platforms which may be reusable in some embodiments and disposable in others.

An apparatus (100) for additive manufacturing of a part of an article from a first material comprising particles having a first composition is provided. The apparatus (100) comprises a layer providing means (110) for providing a first support layer from a second material comprising particles having a second composition, wherein the first composition and the second composition are different. The apparatus (100) comprises a concavity defining means (120) for defining a first concavity in an exposed surface of the first support layer. The apparatus (100) comprises a depositing means (130) for depositing a part of the first material in the first concavity defined in the first support layer. The apparatus (100) comprises a levelling means (140) for selectively levelling the deposited first material in the first concavity. The apparatus (100) comprises a first fusing means (150) for fusing some of the particles of the levelled first material in the first concavity by at least partially melting said particles, thereby forming a first part of the layer of the article. In this way, the second material may be thus used to provide a support structure during additive manufacturing of the part of the article.

Disclosed is a method of providing control data for an additive manufacturing device. The method includes accessing computer-based model data of at least a portion of the object to be manufactured, generating at least one data model of a region of a building material layer to be selectively solidified for manufacturing the at least one object portion. The data model specifies solidification of the building material, and the end point of the at least one solidification path a set of energy introduction parameter values is specified which generates a reference value for the radiation power per unit area in the radiation impact area of the beam bundle on the building material which is lower than the reference value for the radiation power per unit area at other locations of the solidification path, and providing control data corresponding to the generated at least one data model for generating a control data set for the additive manufacturing device.

Disclosed is a method of providing control data for an additive manufacturing device. The method includes accessing computer-based model data of at least a portion of the object to be manufactured, generating at least one data model of a region of a building material layer to be selectively solidified for manufacturing the at least one object portion. The data model specifies solidification of the building material, and the end point of the at least one solidification path a set of energy introduction parameter values is specified which generates a reference value for the radiation power per unit area in the radiation impact area of the beam bundle on the building material which is lower than the reference value for the radiation power per unit area at other locations of the solidification path, and providing control data corresponding to the generated at least one data model for generating a control data set for the additive manufacturing device.