Multi-directional binder jetting additive manufacturing

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.

1 . A method of additive manufacturing of an object, the method comprising:
 moving a hopper over a volume defined by a print box;   as the hopper moves over the volume, rotating a plurality of dispensing rollers disposed along a dispensing region defined by the hopper, the rotation of the plurality of dispensing rollers moving a powder toward the volume from the dispensing region;   spreading the powder along the volume to form a layer of the powder; and   in a controlled two-dimensional pattern, ejecting a binder from at least one ejection orifice of a print carriage to the layer of the powder to form a portion of the object.   
     
     
         2 . The method of  claim 1 , wherein rotation of the plurality of dispensing rollers moves the powder toward the volume through a gap defined between the plurality of dispensing rollers. 
     
     
         3 . The method of  claim 2 , wherein the gap and the dispensing region span a dimension of the volume substantially perpendicular to a direction of movement of the hopper over the volume. 
     
     
         4 . The method of  claim 1 , wherein rotating the plurality of dispensing rollers includes counter-rotating dispensing rollers of the plurality of dispensing rollers. 
     
     
         5 . The method of  claim 1 , wherein rotating the plurality of dispensing rollers includes controlling a rotation speed of at least one dispensing roller of the plurality of dispensing rollers based on a speed of movement of the hopper over the volume. 
     
     
         6 . The method of  claim 1 , wherein rotating the plurality of dispensing rollers includes controlling a rotation speed of at least one dispensing roller of the plurality of dispensing rollers based on position of the hopper over the volume.