Devices, systems, and methods are directed to the use of vapor phase change in binder jetting processes for forming three-dimensional objects. In general, a vapor of a first fluid may be directed to a layer of a powder spread across a build volume. The vapor may condense to reduce mobility of the particles of the powder of the layer. For example, the condensing vapor may reduce the likelihood of particle ejection from the layer and, thus, may reduce the likelihood of clogging or otherwise degrading a printhead used to jet a second fluid (e.g., a binder) to the layer. Further, or instead, the condensing vapor may increase the density of the powder in the layer which, when repeated over a plurality of layers forming a three-dimensional object, may reduce the likelihood of slumping of the part during sintering.

Devices, systems, and methods are directed to the use of vapor phase change in binder jetting processes for forming three-dimensional objects. In general, a vapor of a first fluid may be directed to a layer of a powder spread across a build volume. The vapor may condense to reduce mobility of the particles of the powder of the layer. For example, the condensing vapor may reduce the likelihood of particle ejection from the layer and, thus, may reduce the likelihood of clogging or otherwise degrading a printhead used to jet a second fluid (e.g., a binder) to the layer. Further, or instead, the condensing vapor may increase the density of the powder in the layer which, when repeated over a plurality of layers forming a three-dimensional object, may reduce the likelihood of slumping of the part during sintering.

A structure for delivering a flow of gas across a window or aperture of an imaging or measurement device within an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, the structure comprising: a hollow body having an upper aperture for mounting in correspondence with the window/aperture of said device, a gas flow intake region below the upper aperture, and a lower aperture; wherein the gas flow intake region is provided on opposing sides of the hollow body when viewed in cross-section along a longitudinal axis that runs from the upper aperture to the lower aperture, and comprises one or more channels configured to allow, in use, a flow of intake gas to enter the hollow body from the opposing sides of the hollow body with a flow component that predominantly lies in a plane parallel to the plane of the upper aperture, and to come into confluence within the hollow body; and wherein the hollow body is symmetrically shaped about the longitudinal axis so as to redirect the confluent flow of intake gas to form a substantially axial flow of gas along the longitudinal axis, and a backflow of gas near the internal wall of the hollow body, wherein the upper aperture is substantially shielded from the backflow by the intake flow, and wherein the velocity of the backflow is relatively low in comparison to the velocity of the intake flow. Also provided is an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, incorporating such a structure, and a method of delivering a flow of gas using such a structure.

A structure for delivering a flow of gas across a window or aperture of an imaging or measurement device within an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, the structure comprising: a hollow body having an upper aperture for mounting in correspondence with the window/aperture of said device, a gas flow intake region below the upper aperture, and a lower aperture; wherein the gas flow intake region is provided on opposing sides of the hollow body when viewed in cross-section along a longitudinal axis that runs from the upper aperture to the lower aperture, and comprises one or more channels configured to allow, in use, a flow of intake gas to enter the hollow body from the opposing sides of the hollow body with a flow component that predominantly lies in a plane parallel to the plane of the upper aperture, and to come into confluence within the hollow body; and wherein the hollow body is symmetrically shaped about the longitudinal axis so as to redirect the confluent flow of intake gas to form a substantially axial flow of gas along the longitudinal axis, and a backflow of gas near the internal wall of the hollow body, wherein the upper aperture is substantially shielded from the backflow by the intake flow, and wherein the velocity of the backflow is relatively low in comparison to the velocity of the intake flow. Also provided is an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, incorporating such a structure, and a method of delivering a flow of gas using such a structure.

An additive manufacturing system including a base assembly and a tray assembly. The base assembly includes a build window, substantially transparent to electromagnetic radiation; a projection system configured to project electromagnetic radiation toward an upper surface of the build window; and a tray seat arranged around a perimeter of the build window. The tray assembly is configured to engage with the base assembly in an engaged configuration and includes: a tray structure defining a registration feature configured to engage the tray seat to locate an aperture proximal to the upper surface of the build window in the engaged configuration; and a separation membrane that is configured to laminate across the upper surface of the build window in response to an evacuation of gas from an interstitial region and configured to separate from the build window in response to injection of gas into the interstitial region.

An additive manufacturing system including a base assembly and a tray assembly. The base assembly includes a build window, substantially transparent to electromagnetic radiation; a projection system configured to project electromagnetic radiation toward an upper surface of the build window; and a tray seat arranged around a perimeter of the build window. The tray assembly is configured to engage with the base assembly in an engaged configuration and includes: a tray structure defining a registration feature configured to engage the tray seat to locate an aperture proximal to the upper surface of the build window in the engaged configuration; and a separation membrane that is configured to laminate across the upper surface of the build window in response to an evacuation of gas from an interstitial region and configured to separate from the build window in response to injection of gas into the interstitial region.

A method for additive manufacturing includes: at a build tray arranged over a build window and containing a resin reservoir of a resin, heating the resin reservoir toward a target bulk resin temperature less than a heat deflection temperature of the resin in a photocured state; at a resin interface between a surface of the build window and the resin reservoir, heating an interface layer of the resin reservoir toward a target reaction temperature; and, in response to the resin reservoir exhibiting a first temperature proximal the target bulk resin temperature and to the interface layer exhibiting a second temperature proximal the target reaction temperature: at the resin interface, selectively photocuring a first volume of the resin to form a first layer of a build adhered to a build platform; and retracting the build platform away from the build window.

A method for additive manufacturing includes: at a build tray arranged over a build window and containing a resin reservoir of a resin, heating the resin reservoir toward a target bulk resin temperature less than a heat deflection temperature of the resin in a photocured state; at a resin interface between a surface of the build window and the resin reservoir, heating an interface layer of the resin reservoir toward a target reaction temperature; and, in response to the resin reservoir exhibiting a first temperature proximal the target bulk resin temperature and to the interface layer exhibiting a second temperature proximal the target reaction temperature: at the resin interface, selectively photocuring a first volume of the resin to form a first layer of a build adhered to a build platform; and retracting the build platform away from the build window.

A biofabrication system includes a workstation and an articulating arm disposed within a work area of a biosafety cabinet. The workstation includes a stage for biofabrication. The biosafety cabinet includes an integration port that provides access to the work area through a wall of the biosafety cabinet. The articulating arm may be positioned to reach the workstation and the integration port.

A biofabrication system includes a workstation and an articulating arm disposed within a work area of a biosafety cabinet. The workstation includes a stage for biofabrication. The biosafety cabinet includes an integration port that provides access to the work area through a wall of the biosafety cabinet. The articulating arm may be positioned to reach the workstation and the integration port.