In a method of building up a component in layers from photopolymerizable material, in particular a resin with ceramic or metallic filler, in which component layers are successively formed one above the other by forming a layer of the highly viscous photopolymerizable material between a building platform or the component and a material carrier, which is cured in a location-selective manner to form the desired shape of the component layer, a cleaning step takes place after the component layer has been formed, in which uncured photopolymerizable material adhering to the component layer is removed by means of a cleaning unit after the component has been lifted.

A method (1000) of additively manufacturing an object (200) from a powder material (202) comprises discharging the powder material (202) from a powder-deposition opening (126) in a hollow body (122) of a powder-supply arm (108) while rotating the powder-supply arm (108) and an energy-supply arm (112) about a vertical axis A1. Method (1000) also comprises, while rotating the powder-supply arm (108) and the energy-supply arm (112) about the vertical axis A1, distributing the powder material (202) within a powder-bed volume (204) using a powder-distribution blade (128) that is coupled to the hollow body (122) and extends along the powder-deposition opening (126). The method (1000) further comprises, while rotating the powder-supply arm (108) and the energy-supply arm (112) about vertical axis A1, consolidating at least a portion of the powder material (202) in the powder-bed volume (204) using the energy emitters (114), coupled to the energy-supply arm (112).

Methods and assemblies for additive manufacturing portions of components with enhanced strength are provided. The assemblies comprise a first deposition head and an apparatus for causing one or more reinforcement fibers to extend more than two layers within previously-deposited layers of build material. The first deposition head is configured to deposit a plurality of layers of a filament comprising a reinforcement fiber and thermoplastic material. The apparatus may comprise a needle point configured to be inserted into the plurality of layers to displace the reinforcement fiber so that it extends two or more of the plurality of layers. The apparatus may additionally or alternatively comprise a second deposition head having a needle tip configured to be inserted into the plurality of layers to inject a length of a second filament comprising thermoplastic material and a reinforcement fiber so that the reinforcement fiber of the second filament extends two or more layers of the plurality of layers of the first filament.

A fabrication system is operable to form a structure (such as on a substrate) using a combination of a first (electrically) non-conductive material and a second (electrically) non-conductive. In one embodiment, the structure defined by the first material and the second material defines a void (passageway) in the structure. In one embodiment, exposed surfaces of the first non-conductive material and the second non-conductive material define the void in the structure. Subsequent to creating the structure including the void, the fabrication system fills the void (such as via injection) with an electrically conductive material. After the injected electrically conductive material (such as metal epoxy or other suitable material) solidifies, the fabrication system removes the first non-conductive material (sacrificial material) from the structure. The remaining second material provides structural support for the electrically conductive material.

A method of fabricating an object in layers, comprises, for at least one layer: dispensing a building material formulation to form a first portion of the layer, and leveling the first portion by a leveling device; increasing a vertical distance between the first portion and the leveling device; and while a topmost surface of the first portion is exposed and beneath a segment of the leveling device: dispensing a building material formulation to form a second portion of the layer, laterally displaced from the first portion along an indexing direction, and leveling the second portion by the leveling device.

Methods and apparatus for the fabrication of solid three-dimensional objects from liquid polymerizable materials at high resolution. A material is coated on a film non-digitally, excess material is removed digitally, by laser, leaving an image of a layer to be printed, and the image is then engaged with existing portions of an object being fabricated and exposed to a non-digital heat source. Since the only part of the process that is digital is the material removal, and this part is done by laser, the speed of printing and the robustness of the manufacturing process is improved significantly over conventional additive or 3D fabrication techniques.

Methods and apparatus for the fabrication of solid three-dimensional objects from liquid polymerizable materials at high resolution. A material is coated on a film non-digitally, excess material is removed digitally, by laser, leaving an image of a layer to be printed, and the image is then engaged with existing portions of an object being fabricated and exposed to a non-digital heat source. Since the only part of the process that is digital is the material removal, and this part is done by laser, the speed of printing and the robustness of the manufacturing process is improved significantly over conventional additive or 3D fabrication techniques.

Build material handling unit (2) for a powder module (3) for an apparatus for additively manufacturing three-dimensional objects, which apparatus is adapted to successively layerwise selectively irradiate and consolidate layers of a build material (4) which can be consolidated by means of an energy source, wherein the build material handling unit (2) is coupled or can be coupled with a powder module (3), wherein the build material handling unit (2) is adapted to level and/or compact a volume of build material (4) arranged inside a powder chamber (5) of the powder module (3) by controlling the gas pressure inside the powder chamber (5).

A method of additive manufacturing a part via vat photopolymerization (VPP) includes irradiating a first material through a first transparent wall of a first material tank and forming a first section of an nth layer of the part on a platform, positioning the platform with the first section of the nth layer in a second material tank with a distance between the first section of the nth layer and a second transparent wall, and irradiating a second material such that a second section of the nth layer of the part is formed on the platform adjacent to the first section of the nth layer. The method repeats forming first and second sections of additional layer until a predetermined number of total layers are formed. Positioning the first and second sections with a distance between the second and first transparent walls, respectively, inhibits crashing during forming of the part.

A three-dimensional printing apparatus for manufacturing a three-dimensional object includes a controller comprising a signal generator and a three-dimensional printer. The three-dimensional printer includes a print head, a three-dimensional object carrier, and an electrical field applicator. The electrical field applicator is disposed on an end of the print head. The controller is in communication with the print head, part carrier, and electrical field applicator. The three dimensional printer builds the three-dimensional object onto the three-dimensional object carrier. The signal generator outputs a signal to the electrical field applicator and the electrical field applicator generates an electrical field incident to the three-dimensional object on three-dimensional object carrier.