The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.

An apparatus and method for the automated manufacturing of three-dimensional (3D) composite-based objects is disclosed. The apparatus comprises a material feeder, a printer, a powder system, a transfer system, and optionally a fuser. The method comprises inserting a stack of substrate sheets into a material feeder, transferring a sheet of the stack from the material feeder to a printer, depositing fluid on the single sheet while the sheet rests on a printer platen, transferring the sheet from the printer to a powder system, depositing powder onto the single sheet such that the powder adheres to the areas of the sheet onto which the printer has deposited fluid, removing any powder that did not adhere to the sheet, optionally melting the powder on the substrate, and repeating the steps for as many additional sheets as required for making a specified 3D object.

A method for producing a component layer-by-layer includes: providing two or more resin handling assemblies, each including a resin support which has at least a portion which is transparent, each resin support defining a build surface located in a build zone of the respective assembly; executing a build cycle, including: depositing on each build surface radiant-energy-curable resin, the resin on each build surface being a unique material combination; positioning a stage relative to one of the build surfaces to define a layer increment; selectively curing the resin using applied radiant energy so as to define a cross-sectional layer of the component; separating the component from the build surface; cleaning at least one of the component and the stage; and repeating the cycle, for a plurality of layers, wherein at least one of the layers is cured in each of the build zone. Apparatus is described for carrying out the method.

A method for producing a component layer-by-layer includes: providing two or more resin handling assemblies, each including a resin support which has at least a portion which is transparent, each resin support defining a build surface located in a build zone of the respective assembly; executing a build cycle, including: depositing on each build surface radiant-energy-curable resin, the resin on each build surface being a unique material combination; positioning a stage relative to one of the build surfaces to define a layer increment; selectively curing the resin using applied radiant energy so as to define a cross-sectional layer of the component; separating the component from the build surface; cleaning at least one of the component and the stage; and repeating the cycle, for a plurality of layers, wherein at least one of the layers is cured in each of the build zone. Apparatus is described for carrying out the method.

A de-powdering basket comprises an enclosure of at least one side wall and a bottom wall. The enclosure is configured such that, when the enclosure is disposed within a build box, the outer surfaces of the at least one side wall are substantially adjacent to the interior walls of the build box. The enclosure further comprises one or more apertures disposed within the at least one side wall, each of the apertures comprising a void that extends through the at least one side wall from an interior surface of the side wall to an exterior surface of the side wall. The enclosure may be configured to accommodate a build plate situated within the enclosure. Outer edges of the build plate may cooperate with inner surfaces of the side walls of the enclosure to prevent loose powder from passing between the outer edges of the build plate and the side walls.

A de-powdering basket comprises an enclosure of at least one side wall and a bottom wall. The enclosure is configured such that, when the enclosure is disposed within a build box, the outer surfaces of the at least one side wall are substantially adjacent to the interior walls of the build box. The enclosure further comprises one or more apertures disposed within the at least one side wall, each of the apertures comprising a void that extends through the at least one side wall from an interior surface of the side wall to an exterior surface of the side wall. The enclosure may be configured to accommodate a build plate situated within the enclosure. Outer edges of the build plate may cooperate with inner surfaces of the side walls of the enclosure to prevent loose powder from passing between the outer edges of the build plate and the side walls.

Apparatuses and methods for removing support material from and/or smoothing surfaces of an additive-manufactured part are disclosed. Apparatuses may include a spraying chamber, a support surface within the spraying chamber, and one or more nozzles having the ability to spray a fluid at the additive-manufactured parts. The fluid may include a liquid and solid particles carried by the liquid. The support surface may have the ability to support the additive manufactured part. The apparatus may include a tank having the ability to hold at least some of the fluid. A heater may be included for heating the fluid to a desired temperature.

Apparatuses and methods for removing support material from and/or smoothing surfaces of an additive-manufactured part are disclosed. Apparatuses may include a spraying chamber, a support surface within the spraying chamber, and one or more nozzles having the ability to spray a fluid at the additive-manufactured parts. The fluid may include a liquid and solid particles carried by the liquid. The support surface may have the ability to support the additive manufactured part. The apparatus may include a tank having the ability to hold at least some of the fluid. A heater may be included for heating the fluid to a desired temperature.

The present invention concerns methods of forming a three-dimensional object, and polymerizable liquids such as dual cure resins useful for making a three-dimensional object by sterolithography, such as by continuous liquid interface production (CLIP).

The present invention concerns methods of forming a three-dimensional object, and polymerizable liquids such as dual cure resins useful for making a three-dimensional object by sterolithography, such as by continuous liquid interface production (CLIP).