Abstract: A camera assembly is employed in additive manufacturing to improve the fidelity of a printed object. The camera may scan the surface of a build plate of a 3D printer and an object as it is being printed to generate image data. The image data is processed to detect errors in the build plate or printed object. The printer compensates for the detected errors, which can including modifying the printer configuration and/or modifying the instructions for printing a given object. Using the updated configuration, subsequent objects may then be printed, under a corrected process, to produce an object with fidelity to an original object model.

Abstract: Techniques for debinding additively fabricated parts are described that do not require solvent debinding or catalytic debinding, and that may be performed using only thermal debinding in a furnace. As a result, in at least some cases debinding and sintering may take place sequentially within a single furnace. In some embodiments, the techniques may utilize particular materials as binders that allow for a thermal debinding process that does not negatively affect the parts.

Abstract: A method of recycling build material powder including collecting in a keg an amount of excess build material powder during the additive manufacturing of a part cake. The part cake and keg are transferred to a de-powdering station. The part cake is de-powdered to release a mixture of reusable powder and contaminants. The mixture is sieved to remove the contaminants and deposit the reusable powder to the keg.

Abstract: Methods of additive manufacturing, binder compositions for additive manufacturing, and articles produced by and/or associated with methods of additive manufacturing are generally described.

Abstract: Methods provide for fabricating objects through additive manufacturing in a manner that compensates for deformations introduced during post-print processing, such as sintering. An initial model may be divided into a plurality of segments, the initial model defining geometry of an object. For each of the segments, modified geometry may be calculated, where the modified geometry compensates for a predicted deformation. Print parameters can then be updated to incorporate the modified geometry, where the print parameters define geometry of the printed object (e.g., configuration settings of the printer, a tool path, an object model). The object may then be printed based on the updated print parameters.

Abstract: An additive manufacturing system, and corresponding method, prints a sacrificial component using a 3D printing system that includes a spreading mechanism for spreading unbound powder to form layers of a powder bed and a printing mechanism for jetting binder fluid into the unbound powder to form the sacrificial component. The system forms the sacrificial component with a feature that provides a resistive force to a shear force imposed by the spreading mechanism during the spreading. The system prints a part with the 3D printing system in a coupled arrangement with the sacrificial component. The coupled arrangement in combination with the resistive force is sufficient to immobilize each printed layer of the part to resist the shear force imposed by the spreading mechanism during spreading of the unbound powder above each printed layer of the part. After printing, and before or after post-processing, the part and sacrificial component are separated.

Abstract: A method of maintaining part geometry fidelity during infiltration of a metallic preform. The preform and an infiltration barrier are formed, either independently or together during an additive manufacturing process. The infiltration barrier prevents infiltrant from bleeding out from the preform where it is present, thus protecting fine geometries that would otherwise be filled with infiltrant.

Abstract: A sintering furnace may include a furnace chamber and a retort located within the furnace chamber that receives a part to be heated. The furnace may also include one or more heating elements positioned around the retort and a power controller including power modules connected in series. The power modules may be operably connected to the one or more heating elements and may provide a direct current (DC) power output. A controller may selectively control the power modules to supply power to the one or more heating elements.

Abstract: 3D printing using certain materials, such as metal containing multi-phase materials can be prone to clogs and other flow interruptions. Providing build material according to feed rate profiles having varying rates can mitigate these problems. Each feed rate profile can be broken up into blocks of time, some of which relate to fabricating the exterior geometry of the object. Each block of time can be represented by a FFT. The blocks that relate to the exterior are represented by a FFT that has significant high frequency content of 1 Hz or greater. It is beneficial to use profiles including feed rates outside of a range of feed rates suitable for steady state extrusion, being either higher or lower rates than the range limits. A combination of feed rate profiles based only on clog and flow interruption mitigation and operational to print the part according to a model can be used.

Abstract: Systems and methods for forming an object using additive manufacturing. One method includes receiving a digital model of the object, predicting a shrinking characteristic or receiving a predicted shrinking characteristic of the object that will occur during thermal processing of the object, once formed, and generating, based on the shrinking characteristic of the object, instructions for forming a raft on which the object will be formed. The instructions for forming the raft are configured to form a raft having a shrinking characteristic that reflects the shrinking characteristic of the object.

Abstract: A compound sintering furnace with managed contamination for debinding and sintering parts. An inner insulation layer is disposed within an outer insulation layer and has an internal hot face surrounding a work zone. A sealed housing surrounds the inner insulation layer and is composed of a refractory material capable of withstanding a service temperature greater than a debinding temperature and less than a sintering temperature. An outer heater system is configured to heat at least a portion of the sealed housing and externally heat the inner insulation layer to, in conjunction with an inner heater system, heat the work zone to the debinding temperature, and inhibit condensation of a binder within and upon the inner insulation layer during a debinding process. The inner heater system is configured to internally heat the inner insulation and heat the work zone to the sintering temperature.

Abstract: A system and corresponding method for additive manufacturing of a three-dimensional (3D) object to improve packing density of a powder bed used in the manufacturing process. The system and corresponding method enable higher density packing of the powder. Such higher density packing leads to better mechanical interlocking of particles, leading to lower sintering temperatures and reduced deformation of the 3D object during sintering. An embodiment of the system comprises means for adjusting a volume of a powder metered onto a top surface of the powder bed to produce an adjusted metered volume and means for spreading the adjusted metered volume to produce a smooth volume for forming a smooth layer of the powder with controlled packing density across the top surface of the powder bed. The controlled packing density enables uniform shrinkage, without warping, of the 3D object during sintering to produce higher quality 3D printed objects.

Abstract: Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from additively fabricated parts through liquid immersion of the parts. Motion of the liquid, such as liquid currents, may dislodge or otherwise move powder away from additively fabricated parts to which it is adhered or otherwise proximate to. The liquid may also provide a vehicle to carry away powder from the additively fabricated parts. Removed powder may be filtered or otherwise separated from the liquid to allow recirculation of the liquid to the parts and/or to enable re-use of the powder in subsequent additive fabrication processes. Techniques for depowdering through liquid immersion may be automated, thereby mitigating challenges associated with manual depowdering operations.

Abstract: Devices, systems, and methods are directed to the use of vapor phase change in binder jetting processes for forming three-dimensional objects. In general, a vapor of a first fluid may be directed to a layer of a powder spread across a build volume. The vapor may condense to reduce mobility of the particles of the powder of the layer. For example, the condensing vapor may reduce the likelihood of particle ejection from the layer and, thus, may reduce the likelihood of clogging or otherwise degrading a printhead used to jet a second fluid (e.g., a binder) to the layer. Further, or instead, the condensing vapor may increase the density of the powder in the layer which, when repeated over a plurality of layers forming a three-dimensional object, may reduce the likelihood of slumping of the part during sintering.

Abstract: Methods of additive manufacturing, binder compositions for additive manufacturing, and articles produced by and/or associated with methods of additive manufacturing are generally described.

Abstract: Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts through vibration of the powder, the parts, and/or structures mechanically connected to the powder and/or parts. For instance, the application of vibration may dislodge, aerate and/or otherwise increase the flowability of regions of the powder, thereby making it easier to remove the powder with a suitable means. Techniques for depowdering through vibration may be automated, thereby mitigating challenges associated with manual depowdering operations.

Abstract: Techniques for depowdering in additive fabrication are provided. According to some aspects, techniques are provided that separate powder from parts by directing gas onto, or near to, the powder. While fragile green parts, such as green parts produced by binder jetting, may be fragile with respect to scraping or impacts, such parts may nonetheless be resistance to damage from directed gas, even if directed at a high pressure. Techniques for depowdering through directed application of gas may be automated, thereby mitigating challenges associated with manual depowdering operations.

Abstract: An additive manufacturing system, and corresponding method, prints a sacrificial component using a 3D printing system that includes a spreading mechanism for spreading unbound powder to form layers of a powder bed and a printing mechanism for jetting binder fluid into the unbound powder to form the sacrificial component. The system forms the sacrificial component with a feature that provides a resistive force to a shear force imposed by the spreading mechanism during the spreading. The system prints a part with the 3D printing system in a coupled arrangement with the sacrificial component. The coupled arrangement in combination with the resistive force is sufficient to immobilize each printed layer of the part to resist the shear force imposed by the spreading mechanism during spreading of the unbound powder above each printed layer of the part. After printing, and before or after post-processing, the part and sacrificial component are separated.