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: Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

Abstract: A method is provided for printing a three-dimensional object. The method comprises, depositing a layer of metal powder onto a powder bed of a three-dimensional printer. A liquid is heated to generate a vapor. The liquid is removed from the vapor to dry the vapor by heating the vapor above a condensation temperature of the liquid. The dry vapor is deposited onto the powder bed of the three-dimensional printer.

Abstract: The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

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: The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

Abstract: Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

Abstract: A method of conditioning layers of build material powder for metal additive manufacturing including depositing an amount of build material powder on a work surface, the amount of build material powder having a lower surface separated from an upper surface by a height. A roller is traversed across the work surface in a first direction while rotating the roller in a direction opposed to the first direction. During the step of traversing the roller, a lower surface of the roller extends below the upper surface of the amount of build material powder by a distance. The roller has a surface conditioning configured to, in conjunction with a controlled speed of the rotation of the roller, provide a powder density in a compacted layer within a predetermined powder density range.

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: Embodiments described herein relate to methods and systems for controlling the packing behavior of powders for additive manufacturing applications. In some embodiments, a method for additive manufacturing includes adding a packing modifier to a base powder to form a build material. The build material may be spread to form a layer across a powder bed, and the build material may be selectively joined along a two-dimensional pattern associated with the layer. The steps of spreading a layer of build material and selectively joining the build material in the layer may be repeated to form a three-dimensional object. The packing modifier may be selected to enhance one or more powder packing and/or powder flow characteristics of the base powder to provide for improved uniformity of the additive manufacturing process, promote sintering, and/or to enhance the properties of the manufactured three-dimensional objects.

Abstract: A method of metal additive manufacturing, including forming a three-dimensional object as a successive series of layers. At least some of the successive layers is formed by depositing a layer of build material powder on a work surface, depositing a predetermined pattern of fugitive fluid and depositing a predetermined pattern of binder fluid, wherein the predetermined pattern of fugitive fluid improves at least one characteristic of the three-dimensional part.

Abstract: Systems and methods are disclosed for forming a three-dimensional object using additive manufacturing. One method includes depositing a first amount of powder material onto a powder print bed of a printing system, spreading the first amount of powder material across the powder print bed to form a first layer, measuring a density of powder material within the powder print bed, and adjusting a parameter of the printing system based on the measured density of the powder material within the powder print bed.

Abstract: The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

Abstract: Devices, systems, and methods are directed to the use of nanoparticles for improving strength fabrication of three-dimensional objects formed through layer-by-layer process in which an ink is delivery of a binder delivered onto successive layers of a powder of inorganic particles in a powder bed. More specifically, nanoparticles of inorganic material can may be introduced into one or more layers of the metal powder in the powder bed and thermally processed to facilitate sinter necking, in the powder bed, of the metal particles forming the three-dimensional object. Such sinter necking in the powder bed can may improve strength of the three-dimensional objects being fabricated and, also or instead, can may reduce the likelihood of defects associated with subsequent processing of the three-dimensional objects (e.g., slumping and shrinking in a final sintering stage and/or inadequate densification of the final part).

Abstract: Systems, methods, components, and materials are disclosed for stereolithographic fabrication of three-dimensional, dense objects. A resin including at least one component of a binder system and dispersed particles can be exposed to an activation light source. The activation light source can cure the at least one component of the binder system to form a green object, which can include the at least one component of the binder system and the particles. A dense object can be formed from the green object by removing the at least one component of the binder system in an extraction process and thermally processing particles to coalesce into the dense object.

Abstract: Techniques for depowdering additively fabricated parts are described. The techniques utilize various mechanisms to separate powder from parts. For instance, techniques for depowdering described herein may include fabrication of auxiliary structures in addition to fabrication of parts. Certain auxiliary structures may aid with depowdering operations, and may be fabricated along with parts during an additive fabrication process. The auxiliary structures may be shaped and/or have positional and/or geometrical relationships to the parts during fabrication. For instance, an auxiliary structure may include a cage structure fabricated around one or more parts.

Abstract: An additive manufacturing method includes depositing a first amount of metal powder onto a powder bed of a printing system, spreading the first amount of metal powder across the powder bed to form a first layer, and depositing a first amount of binder material on the first layer. The additive manufacturing method also includes exposing the first layer to a first lighting condition, imaging the first layer under the first lighting condition to generate a first image, analyzing the first image of the first layer, and determining whether to adjust at least one printing parameter based on the analyzing.

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: 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: 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.