An additive manufacturing apparatus is provided. The additive manufacturing apparatus may include a stabilizing system; a build platform on the stabilizing system; and a build unit positioned over the build platform, wherein the build unit comprises a powder dispenser and a recoater blade. Methods are also provided for making an object from powder.

An additive manufacturing apparatus is provided. The additive manufacturing apparatus may include a stabilizing system; a build platform on the stabilizing system; and a build unit positioned over the build platform, wherein the build unit comprises a powder dispenser and a recoater blade. Methods are also provided for making an object from powder.

A method of fabricating a shaped object includes: preparing a formation sheet including a base and a thermally expansive layer stacked on a first main surface of the base, the thermally expansive layer including a binder and thermally expandable material; heating the base of the formation sheet to a temperature lower than an expansion initiation temperature at which the thermally expandable material starts to expand; and heating the thermally expansive layer of the formation sheet after heating of the base, to a temperature higher than or equal to the expansion initiation temperature at which the thermally expandable material starts to expand, thereby causing expansion of the thermally expansive layer.

A method of fabricating a shaped object includes: preparing a formation sheet including a base and a thermally expansive layer stacked on a first main surface of the base, the thermally expansive layer including a binder and thermally expandable material; heating the base of the formation sheet to a temperature lower than an expansion initiation temperature at which the thermally expandable material starts to expand; and heating the thermally expansive layer of the formation sheet after heating of the base, to a temperature higher than or equal to the expansion initiation temperature at which the thermally expandable material starts to expand, thereby causing expansion of the thermally expansive layer.

A layer forming apparatus includes a loading unit including a stage onto which powder is supplied, a rotator that flattens the powder on the stage to form a powder layer, and circuitry. The circuitry causes the rotator to move in a first direction parallel to a surface of the stage and rotate while contacting the powder on the stage to form the powder layer. Further, the circuitry causes the rotator to move in a second direction opposite to the first direction and rotate while contacting surplus powder not on the stage.

An additive manufacturing apparatus includes a platform, a dispenser configured to deliver a plurality of successive layers of feed material onto the platform, at least one light source configured to generate a first light beam and a second light beam, a polygon mirror scanner, an actuator, and a galvo mirror scanner. The polygon mirror scanner is configured to receive the first light beam and reflect the first light beam towards the platform. Rotation of the first polygon mirror causes the light beam to move in a first direction along a path on a layer of feed material on the platform. The actuator is configured to cause the path to move along a second direction at a non-zero angle relative to the first direction. The galvo mirror scanner system is configured to receive the second light beam and reflect the second light beam toward the platform.

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 second layer forming portion is moved in a direction separating from a shaping table before the 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 P from the head, and a first layer forming portion is moved in a direction separating from the shaping table 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 second layer forming portion is moved in a direction separating from a shaping table before the 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 P from the head, and a first layer forming portion is moved in a direction separating from the shaping table before the first layer forming portion faces the shaping region.

A printing apparatus for printing a three-dimensional object comprising an operative surface, at least one supply hopper for depositing layers of powder onto the operative surface and an energy source for emitting at least one energy beam onto the layers of powder. The supply hopper and energy source are configured such that when a topmost layer of powder is being deposited onto an underlying layer of powder on the operative surface, the direction travelled by the supply hopper when depositing the topmost layer is different to the direction travelled by the supply hopper when depositing the underlying layer, and at least one energy beam is emitted onto the topmost layer and at least one further energy beam is emitted onto the underlying layer, simultaneously, to melt, fuse or sinter the topmost and underlying layers.

A printing apparatus for printing a three-dimensional object comprising an operative surface, at least one supply hopper for depositing layers of powder onto the operative surface and an energy source for emitting at least one energy beam onto the layers of powder. The supply hopper and energy source are configured such that when a topmost layer of powder is being deposited onto an underlying layer of powder on the operative surface, the direction travelled by the supply hopper when depositing the topmost layer is different to the direction travelled by the supply hopper when depositing the underlying layer, and at least one energy beam is emitted onto the topmost layer and at least one further energy beam is emitted onto the underlying layer, simultaneously, to melt, fuse or sinter the topmost and underlying layers.