The present invention provides a metal powder-polymer matrix film for use in delivering metal powder to a three-dimensional printing process, the matrix comprising at least one metal powder and a polymer sheet, wherein the metal powder is incorporated within the polymer sheet architecture or on the polymer sheet surface, and wherein the polymer sheet has a thickness that is at least half that of the powder thickness.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control a state of matter of each successive additive layer. Accordingly, the system may be used to alter the chemical bond arrangement of the material forming the various additive layers.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control a state of matter of each successive additive layer. Accordingly, the system may be used to alter the chemical bond arrangement of the material forming the various additive layers.

Methods and apparatus are provided for controlling the temperature of powders in a powder-based additive manufacturing system using spatial light modulation. Powder layer temperatures can be measured and selectively controlled using a radiation source comprising a spatial light modulator. The spatial light modulator applies a visible light radiation and/or IR radiation. In addition to controlling the pre-fused temperature of the powder in the image plane, the spatial light modulator can also apply the radiation to fuse the powder.

Methods and apparatus are provided for controlling the temperature of powders in a powder-based additive manufacturing system using spatial light modulation. Powder layer temperatures can be measured and selectively controlled using a radiation source comprising a spatial light modulator. The spatial light modulator applies a visible light radiation and/or IR radiation. In addition to controlling the pre-fused temperature of the powder in the image plane, the spatial light modulator can also apply the radiation to fuse the powder.

An additive-manufacturing apparatus (100) comprises a support (102) and a powder-material source (106). The additive-manufacturing apparatus (100) further comprises a powder-supply arm (108), which comprises a hollow body (122), having an interior volume (124) that is in communication with the powder-material source (106), a powder-deposition opening (126) in the hollow body (122), and a powder-distribution blade (128), coupled to the hollow body (122) and extending along the powder-deposition opening (126). The additive-manufacturing apparatus (100) also comprises an energy source (110), an energy-supply arm (112), and energy emitters (114), coupled to the energy-supply arm (112). The additive-manufacturing apparatus (100) further comprises a rotary drive (116), configured to rotate the powder-supply arm (108) and the energy-supply arm (112) about a vertical axis A1, passing through the support (102), and intersecting a powder-supply-arm central axis A2 and an energy-supply-arm central axis A3.

Various embodiments relate to forming particles using undercooled metal particles in response to focused low power laser light. Particle growth can be initiated by utilizing the metastable and liquid nature of the particles, allowing for surface instability promoted by the laser light to induce liquid flow to translate to a neighboring particle. This event can cascade radially leading to accumulation of the liquid metal at the epicenter. The grown solidified particle size can be varied by using different power, exposure time, or working distance. Once the liquid has accumulated into a single region, it eventually solidifies either through homogeneous or heterogeneous nucleation to give a solid particle of larger size than the original. Such a method can be used to print patterns on a surface in four dimensions, where the fourth dimension (4D) is attained through gradient in size of the particles made. Additional systems and methods are disclosed.

Various embodiments relate to forming particles using undercooled metal particles in response to focused low power laser light. Particle growth can be initiated by utilizing the metastable and liquid nature of the particles, allowing for surface instability promoted by the laser light to induce liquid flow to translate to a neighboring particle. This event can cascade radially leading to accumulation of the liquid metal at the epicenter. The grown solidified particle size can be varied by using different power, exposure time, or working distance. Once the liquid has accumulated into a single region, it eventually solidifies either through homogeneous or heterogeneous nucleation to give a solid particle of larger size than the original. Such a method can be used to print patterns on a surface in four dimensions, where the fourth dimension (4D) is attained through gradient in size of the particles made. Additional systems and methods are disclosed.

The present disclosure provides methods of making a vitreous bond abrasive article and a metal bond abrasive article. The methods include sequential steps. Step a) includes a subprocess including sequentially: i) depositing a layer of loose powder particles in a confined region; and ii) selectively applying heat via conduction or irradiation, to heat treat an area of the layer of loose powder particles. The loose powder particles include abrasive particles and organic compound particles, as well as vitreous bond precursor particles or metal particles. The layer of loose powder particles has substantially uniform thickness. Step b) includes independently carrying out step a) a number of times to generate an abrasive article preform comprising the bonded powder particles and remaining loose powder particles. Step c) includes separating remaining loose powder particles from the abrasive article preform. Step d) includes heating the abrasive article preform to provide the vitreous bond abrasive article comprising the abrasive particles retained in a vitreous bond material, or to provide the metal bond abrasive article. A method of making a metal bond abrasive optionally includes infusing an abrasive article preform with a molten lower melting metal and solidifying the molten lower melting metal to provide the metal bond abrasive article. The present disclosure further provides a vitreous bond abrasive article precursor and a metal bond abrasive article precursor. Also, methods including receiving, by a manufacturing device having a processor, a digital object specifying data for an abrasive article, and generating the abrasive article with the manufacturing device.

A lifting system serves for use in a manufacturing device for generatively manufacturing a three-dimensional object by layerwise application and selective solidification of a building material. The manufacturing device includes building base on which the object is to be built upon a building surface. The lifting system includes a holding device suitable for holding and height-adjusting the building base. In a position corresponding to an operating state within the manufacturing device, the holding device is arranged in such a way that the building base is attached to the underside of the holding device so that the building surface faces towards the holding device.