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).

A laser beam is irradiated onto material powder on a manufacturing table to solidify the material powder and form a solidified layer. The material powder is further deposited on the solidified layer and the laser beam is irradiated onto one part of the material powder to solidify the material powder. They are repeated to manufacture a manufactured object. An irradiation output value of the laser beam is determined based on measurement information regarding a deposition surface before depositing the material powder or regarding a surface state of the material powder after deposition that is acquired by a camera. Alternatively, the aforementioned irradiation output value is determined based on parity information regarding a number of solidified layers that were already solidified by irradiation of the energy beam, or determined in accordance with an irradiation output value used when solidifying a solidified layer solidified prior to deposition of the deposited material powder.

In a three-dimensional shaped object manufacturing device, when a unit is moved in a forward direction, powder is supplied from a first supply portion, a powder layer is formed by a first layer forming portion, a liquid is discharged to a shaping region from a head, and a shaping table is moved in a direction separating from the unit after discharging the liquid is ended and before a second layer forming portion faces the shaping region, and when the unit is moved in a backward direction, the powder is supplied from a second supply portion, the powder layer is formed by the second layer forming portion, the liquid is discharged to the shaping region from the head, and the shaping table is moved in the direction separating from the unit after discharging the liquid to the shaping region is ended and before the first layer forming portion faces the shaping region.

In a three-dimensional shaped object manufacturing device, when a unit is moved in a forward direction, powder is supplied from a first supply portion, a powder layer is formed by a first layer forming portion, a liquid is discharged to a shaping region from a head, and a shaping table is moved in a direction separating from the unit after discharging the liquid is ended and before a second layer forming portion faces the shaping region, and when the unit is moved in a backward direction, the powder is supplied from a second supply portion, the powder layer is formed by the second layer forming portion, the liquid is discharged to the shaping region from the head, and the shaping table is moved in the direction separating from the unit after discharging the liquid to the shaping region is ended and before the first layer forming portion faces the shaping region.

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.

An improved apparatus and method provide conditioning to a powder deposited on a substrate (e.g., a web), for example, by wetting the powder in a 3D printing apparatus. To achieve this in an exemplary implementation, a wetting apparatus is located between a powder dispenser and at least one top calendering roller in a direction of movement of the substrate, wherein the wetting apparatus is configured to apply a wetting agent to the powder on the substrate before the powder passes through the calendering roller. The wetting agent is comprised of a material which increases cohesiveness of the powder to prevent the powder from adhering to the top roller. In a particular implementation, the wetting agent is steam confined to an area of the substrate where the powder passes through the wetting apparatus, without wetting other areas of the substrate which are not in the wetting apparatus.

An improved apparatus and method provide conditioning to a powder deposited on a substrate (e.g., a web), for example, by wetting the powder in a 3D printing apparatus. To achieve this in an exemplary implementation, a wetting apparatus is located between a powder dispenser and at least one top calendering roller in a direction of movement of the substrate, wherein the wetting apparatus is configured to apply a wetting agent to the powder on the substrate before the powder passes through the calendering roller. The wetting agent is comprised of a material which increases cohesiveness of the powder to prevent the powder from adhering to the top roller. In a particular implementation, the wetting agent is steam confined to an area of the substrate where the powder passes through the wetting apparatus, without wetting other areas of the substrate which are not in the wetting apparatus.

A three-dimensional (“3D”) printing system for printing on a substrate, the printing system including a powder distribution device dispensing powder on the substrate and including a blade-shaped end, the blade-shaped end disposed at a height above the substrate; a powder uniformization device located at a distance from the powder distribution device along a direction substantially parallel to a longitudinal axis of the substrate; one or more sensors disposed upstream from the powder uniformization device and configured to determine one or more parameters of a thickness of the dispensed powder at one or more locations; and a control apparatus configured to determine whether the one or more parameters of the thickness is above a predetermined threshold value, and if the one or more parameters is determined to be above the predetermined threshold value, to adjust the powder distribution device.

A three-dimensional (“3D”) printing system for printing on a substrate, the printing system including a plurality of powder feeders, the plurality of powder feeders dispensing a powder on the substrate in a first direction and in a second direction; and a powder uniformization device located adjacent to the plurality of powder feeders, the powder uniformization device rotatable along the substrate in directions opposing the first direction and the second direction.