In an example implementation, a method of printing a multi-structured three-dimensional (3D) object includes forming a layer of sinterable material. The method includes processing a first portion of the sinterable material using first set of processing parameters and processing a second portion of the sinterable material using a second set of processing parameters. The processed first and second portions form, respectively, parts of a first and second structure of a multi-structured 3D object.

In an example implementation, a method of printing a multi-structured three-dimensional (3D) object includes forming a layer of sinterable material. The method includes processing a first portion of the sinterable material using first set of processing parameters and processing a second portion of the sinterable material using a second set of processing parameters. The processed first and second portions form, respectively, parts of a first and second structure of a multi-structured 3D object.

An exposure control device (31) serves for equipping and/or retrofitting a generative layer-wise building device (1). The latter comprises an exposure device (20) which emits electromagnetic radiation (22) or particle radiation and is configured to irradiate positions to be solidified in a layer in such a way that after cooling they exist as an object cross-section or part of the same. The exposure control device (31) has a first data output interface (36), at which control commands can be output to the exposure device (20). The control commands which are output specify one of a plurality of exposure types wherein an exposure type is defined by a predetermined combination of a radiation energy density to be emitted by the exposure device (20) and a scanning pattern with which the radiation (22) is being directed to a region of a layer of the building material (15). Furthermore, the exposure control device (31) has a second data output interface (37) at which an exposure type can be output in real time in relation to a timing of the output of a control command specifying this exposure type.

The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for the production of at least one desired 3D object. The 3D printer system (e.g., comprising a processing chamber, build module, or an unpacking station) described herein may retain a desired (e.g., inert) atmosphere around the material bed and/or 3D object at multiple 3D printing stages. The 3D printer described herein comprises one or more build modules that may have a controller separate from the controller of the processing chamber. The 3D printer described herein comprises a platform that may be automatically constructed. The invention(s) described herein may allow the 3D printing process to occur for a long time without operator intervention and/or down time.

A recoating unit (40) serves for equipping or retrofitting a device (1) for additive manufacturing of a three-dimensional object (2) by selectively solidifying a building material (15), preferably a powder, layer by layer. The device (1) comprises a recoater (16) movable across a build area (8) for applying a layer (31b, 32b) of the building material (15) within the build area (8) and a solidification device (20) for selectively solidifying the applied layer (31b, 32b) at positions corresponding to a cross-section of the object (2) to be manufactured. The device (1) is formed and/or controlled to repeat the steps of applying and selectively solidifying until the object (2) is completed. The recoating unit (40) comprises at least two recoating rollers (41, 42) spaced apart from each other in a first direction (B1) and extending into a second direction transversely, preferably perpendicularly, to the first direction, and a compacting and/or smoothing element (45) arranged between the two recoating rollers (41, 42) in the first direction (B1) and extending into the second direction. The recoating unit (40) is adapted to draw-out building material to a regular layer (31a, 32a), depending on the movement of the recoating unit into the first direction (B1) or into its reverse direction (B2), using the recoating roller (41, 42) arranged ahead in the respective moving direction (B1, B2), and to compact or smoothen the layer (31a, 32a) drawn-out by the recoating roller (41, 42) arranged ahead using the compacting and/or smoothing element (45).

A recoating unit (40) serves for equipping or retrofitting a device (1) for additive manufacturing of a three-dimensional object (2) by selectively solidifying a building material (15), preferably a powder, layer by layer. The device (1) comprises a recoater (16) movable across a build area (8) for applying a layer (31b, 32b) of the building material (15) within the build area (8) and a solidification device (20) for selectively solidifying the applied layer (31b, 32b) at positions corresponding to a cross-section of the object (2) to be manufactured. The device (1) is formed and/or controlled to repeat the steps of applying and selectively solidifying until the object (2) is completed. The recoating unit (40) comprises at least two recoating rollers (41, 42) spaced apart from each other in a first direction (B1) and extending into a second direction transversely, preferably perpendicularly, to the first direction. At least one of the recoating rollers (41, 42), preferably both of the recoating rollers (41, 42) are formed adjustable in a third direction perpendicular to the first direction and the second direction in the recoating unit (40).

The present disclosure generally relates to methods for additive manufacturing (AM) for fabricating multi-walled structures. A multi-walled structure includes a first wall having a first surface and a second wall having a second surface facing the first surface to define a passage having a width between the first surface and the second surface in a first direction. The multi-walled structure also includes an enlarged powder removal feature connecting the first wall and the second wall. The enlarged powder removal feature has an inner dimension greater than the width in the first direction and at least one open end in a direction transverse to the first width.

The present disclosure generally relates to methods for additive manufacturing (AM) that utilize integrated ribs to support thin walled annular structures. An annular wall fabricated using AM has a thickness less than 0.022 inches across a majority of a surface of the annular wall and a plurality of ribs having a thickness greater than 0.030 inches. The annular wall has a mean thickness less than 0.100 inches. The annular wall conforms to a surface of the component and a mean distance between the annular wall and the component is less than 0.080 inches.

A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive cross sections of the three-dimensional article, the method comprising the steps of: providing a model of the at least one three-dimensional article; applying a first powder layer on a work table; directing a first energy beam from a first energy beam source over the work table causing the first powder layer to fuse in first selected locations according to corresponding models to form a first cross section of the three-dimensional article, where the first energy beam is fusing at least a first region of a first cross section with parallel scan lines in a first direction; varying a distance between two adjacent scan lines, which are used for fusing the powder layer, as a function of a mean length of the two adjacent scan lines.

Additive manufacturing processes featuring consolidation of thermoplastic particulates may form printed objects in a range of shapes. Inorganic nanoparticles disposed upon the outer surface of the thermoplastic particulates may improve flow performance of the thermoplastic particulates during additive manufacturing, but may be undesirable to incorporate in some printed objects. Polymer nanoparticles may be substituted for inorganic nanoparticles in some instances to address this difficulty and provide other advantages. Particulate compositions suitable for additive manufacturing may comprise: a plurality of thermoplastic particulates comprising a thermoplastic polymer and a plurality of polymer nanoparticles disposed upon an outer surface of the thermoplastic particulates, the polymer nanoparticles comprising a crosslinked fluorinated polymer.