Devices and methods for three-dimensional printing

Abstract

The present disclosure provides systems and methods for the formation of three-dimensional objects. A method for forming a three-dimensional object may comprise alternately and sequentially applying a stream comprising a binding substance to an area of a layer of powder material in a powder bed, and generating at least one perimeter of the three-dimensional object in the area. The stream may be applied in accordance with a model design of the three-dimensional object. The at least one perimeter may generated in accordance with the model design.

1 - 21 . (canceled) 
     
     
         22 . A system for forming a three-dimensional object, comprising
 a container that is configured to contain a powder bed;   a binding substance applicator that is configured to apply a binding substance to an area of a layer of powder material in said powder bed;   at least one perimeter generator that is configured to generate at least one perimeter corresponding to said three-dimensional object in said area; and   one or more computer processors operatively coupled to said binding substance applicator and said at least one perimeter generator, wherein said one or more computer processors are individually or collectively programmed to (a) direct said binding substance applicator to apply a stream comprising said binding substance to said area of said layer of powder material in said powder bed, wherein said stream is applied in accordance with a model design of said three-dimensional object, and (b) direct said at least one perimeter generator to generate said at least one perimeter corresponding to said three-dimensional object in said area, wherein said at least one perimeter is in accordance with said model design.   
     
     
         23 . The system of  claim 22 , wherein said at least one perimeter generator is a plurality of perimeter generators. 
     
     
         24 . The system of  claim 22 , wherein said at least one perimeter generator comprises a contact cutter. 
     
     
         25 . The system of  claim 22 , wherein said at least one perimeter generator comprises a multi-axis machine unit, a computer numeric control (CNC) spindle, a cutting tool bit, or a blade. 
     
     
         26 . The system of  claim 22 , wherein said at least one perimeter generator comprises a non-contact cutter. 
     
     
         27 . The system of  claim 26 , wherein said non-contact cutter is a laser. 
     
     
         28 . The system of  claim 22 , wherein said binding substance applicator is a spray outlet or spray head module. 
     
     
         29 . The system of  claim 22 , further comprising a powder dispenser configured to dispense said powder material. 
     
     
         30 . The system of  claim 22 , further comprising a smoother, wherein said smoother is configured to smooth a top surface of said powder bed. 
     
     
         31 . The system of  claim 30 , wherein said smoother is a roller, a blade, a knife, a gas knife, an air knife, or a leveler. 
     
     
         32 . The system of  claim 22 , further comprising an energy source that is configured to provide an energy beam directed to at most a portion of said layer of powder material. 
     
     
         33 . The system of  claim 32 , further comprising one or more computer processors that are individually or collectively programmed to (a) direct said binder application unit to apply a stream comprising said binding substance to an area of a layer of powder material in said powder bed, wherein said stream is applied in accordance with a model design of said three-dimensional object, and (b) direct said energy source to provide said energy beam directed to at most a portion of said layer of powder material, wherein said energy beam is directed in accordance with said model design of said three-dimensional object, wherein said stream has a first cross-sectional dimension and said energy beam has a second cross-sectional dimension, wherein said first cross-sectional dimensional is greater than said second cross-sectional dimensional. 
     
     
         34 . The system of  claim 22 , further comprising a heating source, wherein said heating source is configured to heat a subsection of said area of said layer of powder material. 
     
     
         35 . The system of  claim 22 , wherein said heating source is configured to provide heat, electromagnetic radiation, or resistive heat. 
     
     
         36 . The system of  claim 22 , further comprising an enclosure configured to enclose at least said three-dimensional object. 
     
     
         37 . The system of  claim 36 , wherein said enclosure is configured to be open to air, maintained under vacuum, or maintained in a controlled environment. 
     
     
         38 . The system of  claim 22 , wherein said binding substance applicator is an inkjet head, atomizing sprayer, or a nebulizer. 
     
     
         39 . The system of  claim 38 , wherein said binding substance applicator has a greatest dimension of about 1 millimeter to about 1000 millimeters in size. 
     
     
         40 . A method for forming a three-dimensional object, comprising:
 (a) providing a powder bed comprising powder material;   (b) applying a first binding substance to a first area of a first layer of powder material of said powder bed;   (c) heating a first subsection of said first area, wherein said first subsection is from a model design of said three-dimensional object;   (d) depositing a second layer of powder material adjacent to said first layer;   (e) applying a second binding substance to a second area of said second layer of powder material; and   (f) heating a second subsection of said second area, wherein said second subsection is from said model design of said three-dimensional object.   
     
     
         41 . The method of  claim 40 , wherein at least a portion of said second layer binds to said first layer.