Apparatuses, systems and methods for three-dimensional printing

Abstract

The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.

1 - 30 . (canceled) 
     
     
         31 . A device for generating a planar layer of powder material, the device comprising:
 a dispenser configured to (I) contain powder material and (II) dispense at least a portion of the powder material through an opening to generate a first portion of a powder bed having a first exposed surface;   a shaker configured to shake the at least the portion of the powder material for dispensing from the opening of the dispenser, the shaker (i) being operatively coupled to the dispenser or (ii) being part of the dispenser; and   a remover configured to remove powder material from the first portion of the powder bed to generate a second exposed surface of a second portion of the powder bed at least in part by being configured to operatively couple to an attractive force source to operatively couple the attractive force source with the powder bed, the attractive force attracting powder material from the first portion of the powder bed to generate the planar layer having the second exposes surface as part of the second portion of the powder bed that is a remainder of the first portion of the powder bed.   
     
     
         32 . The device of  claim 31 , wherein the device is configured to dispense the planar layer of powder material while maintaining a gap with the first portion the powder bed such that the device dispenses the planar layer of powder material without contacting the first portion of the powder bed. 
     
     
         33 . The device of  claim 31 , wherein the attractive force comprises vacuum. 
     
     
         34 . The device of  claim 31 , wherein the attractive force comprises a magnetic force, an electric force, or an electrostatic force. 
     
     
         35 . The device of  claim 31 , wherein the shaker comprises an ultrasonic transducer, a piezoelectric device, or a rotating motor. 
     
     
         36 . The device of  claim 31 , wherein the dispenser comprises an opening configured to facilitate flow of the at least the portion of the powder material from the dispenser, and wherein the shaker is configured to vibrate at least a portion of the opening through which the at least the portion of the powder material exits the dispenser. 
     
     
         37 . The device of  claim 31 , wherein the dispenser comprises a slanted plane (a) that is operatively coupled to the opening or (b) that is at least a portion of the opening; and wherein during operation of the dispenser, the dispenser is configured to facilitate flow of the powder material through the opening and on the slanted plane. 
     
     
         38 . The device of  claim 31 , wherein the device is configured to dispense the planar layer of powder material to extend a powder bed that comprises one or more three-dimensional objects protruding from an exposed surface of the powder bed. 
     
     
         39 . The device of  claim 31 , wherein the device is configured to dispense the layer of powder material in an enclosure having a positive pressured atmosphere above an ambient atmosphere external to the enclosure. 
     
     
         40 . The device of  claim 31 , wherein the device is configured to dispense the planar layer that has a deviation from planarity of at most about 30 micrometers. 
     
     
         41 . A system for generating a planar layer of powder material, the system comprising: the device of  claim 31 ; and an energy beam configured to irradiate the planar layer to print at least one three-dimensional object at least in part by using the second portion of the powder bed using three-dimensional printing. 
     
     
         42 . The system of  claim 41 , wherein the system comprises an enclosure in which the at least one three-dimensional object is generated in an atmosphere comprising a positive pressure above an ambient pressure external to the enclosure. 
     
     
         43 . The system of  claim 41 , wherein the system comprises an enclosure in which the at least one three-dimensional object is generated in an atmosphere that comprises oxygen at a level of at most about 10,000 ppm, and water at a level of at most about 1,000 ppm. 
     
     
         44 . The system of  claim 41 , wherein the system comprises a filter configured to capture fine powder from the system, the filter comprising a high-efficiency particulate arresting filter. 
     
     
         45 . An apparatus for generating a planar layer of powder material, the apparatus comprising a control system configured to (i) operatively couple to the device of  claim 31 ; and (ii) direct the device to generate the planar layer. 
     
     
         46 . The apparatus of  claim 45 , wherein the control system is configured to (i) operatively coupled to an energy source, and (ii) direct the energy source to generate an energy beam to print at least one three-dimensional object at least in part by using the second portion of the powder bed. 
     
     
         47 . Non-transitory computer readable program instructions that, when executed by one or more processors operatively coupled to the device of  claim 31 , implement one or more operations comprising directing the device to generate the planar layer. 
     
     
         48 . The non-transitory computer readable program instructions of  claim 47 , wherein the one or more processors are operatively coupled to a scanner, and wherein the operations comprise directing the scanner to translate an energy beam along the second exposes surface to print at least one three-dimensional object at least in part by using the second portion of the powder bed. 
     
     
         49 . A method for generating a planar layer of powder material, the method comprising:
 providing the device of  claim 31 ; and using the device to dispense the planar layer.   
     
     
         50 . The method of  claim 49 , wherein the powder material comprises elemental metal, metal alloy, an allotrope of elemental carbon, or a ceramic. 
     
     
         51 . The method of  claim 49 , further comprising printing at least one three-dimensional object at least in part by using the second portion of the powder bed. 
     
     
         52 . The method of  claim 51 , wherein the at least one three-dimensional object (i) comprises a cavity devoid of auxiliary support and/or (ii) is suspended in the second portion of the powder bed devoid of auxiliary support connected to a base supporting the second portion of the powder bed.