Gas flow in three-dimensional printing

Abstract

The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for controlling and/or treating gas borne debris in an atmosphere of a 3D printer.

1 .- 27 . (canceled) 
     
     
         28 . A system for printing at least one three-dimensional object, the system comprising:
 an enclosure configured to enclose an atmosphere during the printing, the atmosphere being different from an ambient atmosphere external to the enclosure, the enclosure having a floor configured to engage with a platform configured to support the at least one three-dimensional object during the printing, the enclosure comprising:
 a gas inlet portion disposed at a first side of the enclosure, the gas inlet portion being configured to direct a flow of gas along the platform, the gas inlet portion comprising one or more openings, the gas inlet portion comprising a perforated plate configured to flow the gas therethrough and into the enclosure, and 
 a gas outlet portion disposed at a second side of the enclosure opposing the first side, the gas outlet portion configured to direct the flow of gas out of the enclosure via at least one outlet opening contacting the floor of the enclosure, the gas outlet portion comprises a portion having a tapered shape, the portion being tapered towards the at least one outlet opening. 
   
     
     
         29 . The system of  claim 28 , wherein the one or more openings occupy a percentage of height of the enclosure, the percentage being at least about 70% of the height of the enclosure. 
     
     
         30 . The system of  claim 28 , wherein the one or more openings occupy a percentage of depth of the enclosure, the percentage being at least about 70% of the depth of the enclosure. 
     
     
         31 . The system of  claim 28 , wherein the perforated plate comprises a filter. 
     
     
         32 . The system of  claim 28 , wherein the inlet portion comprises a rectangular opening. 
     
     
         33 . The system of  claim 28 , wherein the perforated plate comprises openings that are non-evenly spaced. 
     
     
         34 . The system of  claim 28 , wherein the perforated plate comprises perforations having non-uniform size. 
     
     
         35 . The system of  claim 28 , wherein the outlet portion is configured to reduce an amount of backflow of the gas into the enclosure. 
     
     
         36 . The system of  claim 28 , wherein the system is configured to direct the gas to flow in the enclosure in gas streams, the gas streams being non-evenly spaced across a height of the enclosure. 
     
     
         37 . The system of  claim 28 , wherein the gas flow flows laminarly across at least a portion of the enclosure comprising a processing cone of at least one energy beams utilized in the three-dimensional printing. 
     
     
         38 . The system of  claim 28 , wherein gas flows at different velocities across a height the enclosure. 
     
     
         39 . The system of  claim 28 , wherein the gas flow may comprise flow at a constant, or at a substantially constant, velocity during at least a portion of the three-dimensional printing. 
     
     
         40 . The system of  claim 28 , wherein the gas flow comprises flow at a constant velocity, or at a substantially constant velocity, during operation of one or more energy beams as part of the three-dimensional printing. 
     
     
         41 . The system of  claim 28 , wherein the outlet portion comprises a wall portion that is slanted towards the at least one outlet opening to generate the tapered shape. 
     
     
         42 . The system of  claim 28 , wherein the gas inlet portion further comprises at least one flow aligner having walls configured to direct the flow of gas along the platform. 
     
     
         43 . The system of  claim 42 , wherein the outlet portion comprises a wall portion that is slanted towards the at least one outlet opening to generate the tapered shape, and wherein the at least one flow aligner is more proximate to the platform than the wall portion. 
     
     
         44 . The system of  claim 42 , wherein the at least one flow aligner directs gas within the gas inlet portion toward an outlet port of the gas inlet portion. 
     
     
         45 . The system of  claim 42 , wherein the at least one flow aligner is part of an outlet port section of the gas inlet portion, the outlet port section having an elongated shape. 
     
     
         46 . The system of  claim 42 , wherein the at least one flow aligner is configured to align the flow of gas in the first direction by directing the flow of gas through a plurality of channels. 
     
     
         47 . The system of  claim 46 , wherein the at least one flow aligner has a height of at most about five (5) inches. 
     
     
         48 . The system of  claim 28 , wherein the gas inlet portion is configured to alter a shape, a volume, a velocity, a direction, or an alignment of the flow of gas. 
     
     
         49 . The system of  claim 28 , wherein the system is configured to operatively coupled to, or further comprises, an energy source configured to generate, during the three-dimensional printing, an energy beam for transforming at least a portion of a pre-transformed material to a transformed material as part of the three-dimensional object. 
     
     
         50 . The system of  claim 28 , wherein (I) the gas inlet portion comprises at least one filter configured to reduce an amount of gas-borne material in the enclosure during the three-dimensional printing, (II) the gas outlet portion comprises the at least one filter configured to reduce the amount of gas-borne material in the enclosure during the three-dimensional printing, or (III) the gas inlet portion and the gas outlet portion comprise the at least one filter configured to reduce the amount of gas-borne material in the enclosure during the three-dimensional printing. 
     
     
         51 . The system of  claim 50 , wherein the at least one filter comprises a High-Efficiency Particulate Arrestance (HEPA) filter. 
     
     
         52 . The system of  claim 28 , wherein during the three-dimensional printing, the enclosure is configured to hold a positive pressure above ambient atmosphere external to the enclosure. 
     
     
         53 . A method of passivation of printing the at least one three-dimensional object, the method comprising: (a) providing the system of  claim 28  and (b) using the system to print the at least one three-dimensional object. 
     
     
         54 . An apparatus for printing the at least one three-dimensional object, the apparatus comprising at least one controller having a power connector, which at least one controller is configured control, or direct control of, one or more operations associated with the system of  claim 28 . 
     
     
         55 . A non-transitory computer readable program instructions, the program instructions, when read by at least one processor operatively coupled to the system of  claim 28 , causes the at least one processor to direct operations associated with the system, the program instructions being inscribed on a medium or on a media.