A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.

A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.

The invention relates to a method for producing a three-dimensional shaped object without height limitation by means of layer-by-layer material application, wherein geometric data for the shaped object, a substrate part having a base surface for holding the shaped object, flowable first and second material, and a transfer body are provided. Material portions of the flowable first material are applied to the base surface and/or to a solidified material layer of the three-dimensional shaped object located on the base surface in accordance with the geometric data in order to produce a material layer of the three-dimensional shaped object. The material layer consisting of the first material is solidified. A surface region of the transfer body is coated with a layer of the second material, and said layer is brought into contact with the surface of the topmost solidified material layer of the three-dimensional shaped object facing away from the base surface in such a way that the flowable second material is transferred from the transfer body to the surface of the topmost solidified material layer of the three-dimensional shaped object and forms the further material layer on the surface of the topmost solidified material layer of the three-dimensional shaped object, the structure of which further layer corresponds to the structure of the topmost solidified material layer of the three-dimensional shaped object. The further material layer is likewise solidified.

The invention relates to a method for producing a three-dimensional shaped object without height limitation by means of layer-by-layer material application, wherein geometric data for the shaped object, a substrate part having a base surface for holding the shaped object, flowable first and second material, and a transfer body are provided. Material portions of the flowable first material are applied to the base surface and/or to a solidified material layer of the three-dimensional shaped object located on the base surface in accordance with the geometric data in order to produce a material layer of the three-dimensional shaped object. The material layer consisting of the first material is solidified. A surface region of the transfer body is coated with a layer of the second material, and said layer is brought into contact with the surface of the topmost solidified material layer of the three-dimensional shaped object facing away from the base surface in such a way that the flowable second material is transferred from the transfer body to the surface of the topmost solidified material layer of the three-dimensional shaped object and forms the further material layer on the surface of the topmost solidified material layer of the three-dimensional shaped object, the structure of which further layer corresponds to the structure of the topmost solidified material layer of the three-dimensional shaped object. The further material layer is likewise solidified.

A system and process of printing a package of expanded material (e.g., expanded starch, foam or other expanded material). The expanded material can be heated and extruded, poured, sprayed, or otherwise applied in malleable form that sets up to become a porous protective covering for an item to be packaged. In an example, a layer of expanded material is laid down, and the item in a protective covering (e.g., a plastic bag, sleeve, coating, etc.) is positioned on the layer of expanded material. Additional layers or expanded material may be applied, thereby encasing the item. The top surface of the expanded material may be flattened, such as by operation of a roller, press, or cutter. The top surface may be sprayed with a shellac sealant, paint, or other coating, to allow printing of a label on the top surface.

A system and process of printing a package of expanded material (e.g., expanded starch, foam or other expanded material). The expanded material can be heated and extruded, poured, sprayed, or otherwise applied in malleable form that sets up to become a porous protective covering for an item to be packaged. In an example, a layer of expanded material is laid down, and the item in a protective covering (e.g., a plastic bag, sleeve, coating, etc.) is positioned on the layer of expanded material. Additional layers or expanded material may be applied, thereby encasing the item. The top surface of the expanded material may be flattened, such as by operation of a roller, press, or cutter. The top surface may be sprayed with a shellac sealant, paint, or other coating, to allow printing of a label on the top surface.

A method of additive manufacturing a three-dimensional object by layerwise deposition of a building material with an inkjet printing system comprising a print head and a building tray, comprises calculating a weighting value for each nozzle, then for each layer obtaining a 2-D map of the layer, comprising active pixels at building material dispensing positions; obtaining a Data Correction Filter (DCF) including a height map of the previous layer, comparing the data of the 2D map to the data of the DCF at each position and determining if the nozzle at that position should dispense, then printing the layer, updating the weighting values and adjusting the position of the print head vis a vis the printing tray. The above is repeated until the three-dimensional object is printed.

A method of additive manufacturing a three-dimensional object by layerwise deposition of a building material with an inkjet printing system comprising a print head and a building tray, comprises calculating a weighting value for each nozzle, then for each layer obtaining a 2-D map of the layer, comprising active pixels at building material dispensing positions; obtaining a Data Correction Filter (DCF) including a height map of the previous layer, comparing the data of the 2D map to the data of the DCF at each position and determining if the nozzle at that position should dispense, then printing the layer, updating the weighting values and adjusting the position of the print head vis a vis the printing tray. The above is repeated until the three-dimensional object is printed.

A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.

A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.